Question about 1986 Suzuki Samurai

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How do I change my clutch on an 1986 suzuki samurai

I am having trouble removing the transmission to get to the clutch. Do I have to remove the transmission to replace the clutch?

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I have found it easier to remove the engine to replace the clutch on my 1986 Samurai it you have the proper tools to pull the engine it took less time than pulling the transmission in my experence.

Posted on Jun 28, 2009

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  • Suzuki Master
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The trans must be removed and then the pressure plate wiggle the trans, it will come out the fit is very tight and after years there is some corrosion between the trans and the bell housing mating surfaces, you have to break this free, it can be a real bugger..

Posted on Nov 29, 2008

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1 Answer

How do can you roll start a 86 samurai


Engage two wheel drive. Switch on the ignition. Pull out the choke? Engage second gear and release the hand brake. Depress the clutch pedal and get the vehicle up to about 6-8 mph. Release the clutch and the engine should be turned by the rotation of the wheels - and hopefully start. Once the engine has caught, depress the clutch and keep the engine running in the normal manner.

May 17, 2011 | 1986 Suzuki Samurai

1 Answer

Suzuki samurai starter problems


You are not specific as to what is happening, but most people have the "click-click" problem. If that is it.....it means not enough power getting to the starter solenoid. You can get lucky by removing the wires from the clutch pedal switch and splice them around it to remove the switch resistance. If that does'nt do it completely, you need to get a relay kit from one of the many Samurai suppliers

Feb 08, 2011 | 1988 Suzuki Samurai

1 Answer

1986 suzuki samurai clutch doesn't disengage


throwout bearing possibly, how does the clutch pedal feel?

Apr 03, 2010 | 1987 Suzuki Samurai

1 Answer

Transfer case removal


Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide
Transfer Case Assembly - REMOVAL & INSTALLATION

Samurai Models
Even the 2WD Samurai uses a transfer case. Rather than use a straight line driveshaft from the transmission to the differential, the Samurai leaves the transfer case in place and replaces its internal working with a simple offset gear mechanism, thus keeping 2 of the 3 driveshafts used in the 4WD vehicle.
  1. On 4WD vehicles, remove the transfer case shift lever.
  2. Raise and support the vehicle safely.
  3. Drain the oil from the transfer case.
  4. Matchmark and remove the driveshafts from the transfer case assembly. Not all of the driveshafts need to be completely removed from the vehicle, just unbolted from the case flanges. In most cases, the shaft or shafts on one side of the transfer case can be repositioned and supported out of the way.
  5. Support the transfer case using a suitable transmission jack.
  6. Disconnect the speedometer cable from the transfer case.
  7. On 4WD vehicles, disconnect the 4WD switch lead wire at the coupler.
  8. Remove the three mounting bolts and/or nuts securing the transfer case to the chassis, as applicable.
  9. Carefully lower the transfer case from the vehicle.
To install:
  1. Position and install the transfer case. Tighten the mounting bolts to 159-248 inch lbs. (18-28 Nm) and/or the mounting nuts to 19-25 ft. lbs. (25-34 Nm).
  2. On 4WD vehicles, connect the 4WD switch lead wire at the coupler.
  3. Connect the speedometer cable to the transfer case.
  4. Properly refill the transfer case with an approved type of gear oil.
  5. Align and install the driveshafts to the transfer case.
  6. On 4WD vehicles, install the transfer case shift lever.
  7. Remove the jackstands and carefully lower the vehicle.
Sidekick, Tracker, Sidekick Sport and X-90 Models
On these models the transfer case is bolted to the transmission and takes the place of the 2WD transmission's extension housing. Therefore, transfer case is removed or installed as part of the transmission assembly.

Hope this help (remember rated this and comment).

Mar 21, 2010 | 1993 Geo Tracker

2 Answers

My 1986 suzuki samurai over heats...i have done the following: new head gasket,new thermostate,new water pump,roded out radiator,and the radiator fans works great


are you sure the thermostat is not installed backwards. Remove it and see if you still overheat.

Did you send the head out to be tested for cracks. Did you inspect the block for cracks ??

Feb 13, 2010 | 1986 Suzuki Samurai

1 Answer

Clutch replacement 1986 Samurai


pulling the tansmission is the way to go

Nov 30, 2009 | 1986 Suzuki Samurai

2 Answers

How hard is it to rebuild an 86 Suzuki Samurai 5 speed transmission? I have a tranny tech telling me I need a clutch, flywheel resurface and a remanned unit. How hard could it be. Not 1800$$$! That's Hard....


ITS NOT A HARD JOB. BUT YOU HAVE TO BE CAREFUL.YOU ARE WORKING UNDER A CAR. BESURE TO USE JACK STANDS .YOU NEED A REPAIR MANUAL.IT SHOW YOU HOW TO REMOVE TRANSMISSION.YOU HAVE TO SUPPORT ENGINE WHEN MOVING TRANNY.REBUILT KITS.WILL HAVE ALL GASKETS SEALS AND BEARINGS.BUT MAJOR PARTS YOU HAVE TO BUY THEM SEPERATE.LIKE SHIFT FORK COUNTERSHAFT AND SYNCHRONIZERS.NOW THE CLUTCH KIT IT WILL HAVE CLUTCH PRESSURE PLATE AND CLUTCH RELEASE BEARING.BESURE WHEN YOU BUY KIT MAKE SURE CHECK IT.MAKE SURE IT HAS EVERYTHING YOU NEED.

Jul 22, 2009 | 1987 Suzuki Samurai

2 Answers

From frontto back how are the cylinders numbered?


It usually is the cylinder closest to the crankshaft pulley, if your standing front of the vehicle it should be the one closest to you

Apr 30, 2009 | 1986 Suzuki Samurai

3 Answers

How long will it take to repair a 87 suzuki samurai clutch, 4x4


Remove the shifter from inside, two connectors to the sensorson the trans at the firewall, remove 4 bolts holding front driveshaft to the front diff, slide rear section of front driveshaft out of the splines, remove 4 bolts holding rear driveshaft to transfer case and slide the driveshaft out of the transmission tailshaft, remove the two starter bolts ( hardest part of the job), leave the starter in the engine bay with the wires still attached, remove the clutch ARM from the transmission, remove the rear transmission mount (4 12mm bolts) support the transmission on a jack, put another jack in from of the engine to pitch the engine so the rear is sagging down slightly (this is so you have enough clearance to remove the transmission), remove the four 14 mm bellhousing bolts (remember the longer one goes onto the passenger side top) tip the tailshaft up to the floor of the Sammy and slide it to the rear as far as possible, let the front come down slowly ( it will barley rub the pressure plate but not enough to hurt anything) presto its out, replace the clutch assembly and grease throwout and transmission splines the reverse these steps. I have done 3 of these and accomplished my last one in 4 hours total. No need to remove the exhaust, transfer case or engine as others have stated on numerous write ups. You will need two 12mm combo wrenches, one 14mm combo wrench, one 3/8 drive ratchet with 12mm shortwell socket, a couple extensions for said ratchet, one small pair of pliers (to hold the clutch cable while adjusting) and a hammer to gently tap the clutch arm onto the splines.

Apr 28, 2009 | 1987 Suzuki Samurai

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