Question about 1987 Suzuki Samurai

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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. Do the rebuild kits have everything you need? Which kits are best? What companies? Alan S. FL

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  • Suzuki Master
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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.

Posted on Jul 22, 2009

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  • Master
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It is very time consuming get a used unit new clutch kit and resurface the flywheel

Posted on Jul 22, 2009

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1 Answer

How do I replace just clutch discs?


Pull the transmission. Manual transmission, just pull it and get it out of your way. Get a clutch kit and resurface the flywheel. Automatic transmission, it is a rebuild. either way you need a manual to pull. Then a manual to rebuild the automatic. ATSG.com

Aug 23, 2015 | Cars & Trucks

1 Answer

Why wont my samurai transmission input shaft turn.


5 speed

is it still on the bench>????????
i rebuild many

1: the bearing in the front is bad.
2: the tranny is locked, bad shifter rail, detents
3: 4th gear is not a gear, it just locks themain shaft.
so if in 4th gear and input is jammed, that means
the cluster is jammed. if the cluster jams for any reason
it will be jammed in neutral. too, because the cluster always spins.
bottom counter shaft is called cluster. to old folks.

tell me , with the lid off tranny box.
did you test all gears, by moving the collars 1 by one.?????
each gear,? if not why not.????? never skip this step or fail big time.

then test all rail detents to make sure they all work(lid off)
and never allowing 2 gears selected at once (job1)????

then put in a new shifter sheet and try all gears on the garage floor,
all assembled!
then turn input by and and shift all gears on garage floor
i even use a huge drill motor to test tranny on floor, with tape on tip
of pilot shaft. and shift all gears,

this is all basics, , never just throw it together, do the tests.
as you go.

this one is close,
http://www.fixkick.com/tranny/5speed-rebuild.html


Aug 29, 2014 | 1988 Suzuki Samurai

2 Answers

My clutch on my 1985 Toyota truck has these problems the gears are hard to engage when truck warms up and now when I Release the clutch it moves less then a half an inch and the truck wants to take off can...


I suspect your clutch and pressure plate needs to be replaced,when you depress your pedal to disengage your transmission from your flywheel the pressure plate is not engaging enough to seperate the two it still has a little contact on your flywheel so it is going to be difficult to change gears and your relief is going to be shorter.If you change it out always remember buy a clutch kit with a clutch plate and pressure plate and pilot bushing and slave cylinder all in one kit.Always remove your flywheel and get it resurfaced that is a must ,the flywheels surface will become uneven over time and minimize your surface area on your disc,by getting it resurfaced it will assure your disc has 100% of the flywheel surface for hook up and when you depress your clutch it will clear your flywheel good luck

Jan 15, 2014 | Cars & Trucks

1 Answer

5 speed 4wd. shifter is not working not sure what tranny it is or why wont shift.


Most likely your clutch is out and need to be replaced, If it is a 5 speed manual transmission.
If its an automatic transmission you may need fluid or rebuild.

May 17, 2010 | 1991 Ford F150

1 Answer

How to remove the 5 speed transmission in a 1989 dodge ram 50 to replace the clutch


I can tell you its not easy. I replaced my flywheel. Best way to do it is buy the manual. And make sure you hae a transmission jack. I tried it with a floor jack. But can tell ya though ya got to drop the starter. Top bolt is hard to get to. Gotta disconnect the driveshaft. unbolt it from the motor. But it is recommended to drain the tranny fluid first though

Apr 17, 2010 | 1989 Dodge Ram 50

1 Answer

How hard is it to replace the rear main seal in a '87 Samurai?


Is it a 4x4 if it is you would have to seperate the tranny from transfer case and drive shaft tp change out seal.If not just drop the drive shaft and replace seal.We are talking about the rear seal at the end of the tranny.

May 17, 2009 | 1987 Suzuki Samurai

1 Answer

New clutch and car is still slipping


in some cases if the ther is not enough free play in the clutch pedel as the engine area heats up things will expand in this case the distance of freeplay in your clutch pedel. have your clutch pedel freeplay adjusted. Also it is recomeded NOT to resurface the flywheels on nissans It dose change the hight and the distance for where the fingers of the pressure plate and the release bearing flang contact

Feb 18, 2009 | 1997 Nissan Maxima

1 Answer

My 86 sami lack speed and power


The samurai tranny shifter's wear down and the shift pin tends to break cause slop in the shifter and making it harder to get into 5th gear.

Feb 18, 2009 | 1988 Suzuki Samurai

1 Answer

Instrument panel


These Lights are Telling you that the Transmission and FlyWheel are Either Damaged or are Getting Hot Or Both. I would get the Tranny and Flywheel Checked out before it gets Worse. This could result in a Tranny Rebuild or a New Flywheel. Please Rate My Response! Thanks!

Feb 05, 2009 | 1994 Toyota MR2

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