Question about 1987 Suzuki Samurai
Removed tranny for clutch replacement went well, now having trouble reinstalling shifter. 1990 suzuki samurai.
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Posted on Jan 02, 2017
SOURCE: removing the clutch
I have done this work and its not that hard. You really need access to a garage lift so you can work under the vechile. You can then remove the gearbox after the exhaust. Remove the shift levers and boots but didn't remove anything from the engine. Only trouble i had was when i put it back together the 4wheel shift didn't go in properly but thats because it moved when we took it out. There is a switch on the side to indcate its posistion, make sure you dont damage it and connect it up after.
I do have some photo's if that will help, e-mail me firstname.lastname@example.org and if you need anymore help i'll try to be of service.
Posted on May 22, 2009
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
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.
Posted on Sep 27, 2011
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