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Sammy Re-Build

 
 
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Fri Sep 07, 2018 7:41 am    Post subject: Sammy Re-Build Reply with quote

Well it's time I stared re-furbishing and re-building my old sammy as it's looking pretty sorry for itself these days. I'm not much of an offroader so I'm going to nut and bolt restore and rebuild it for onroad use. All be it with an offroad look i.e lifted a bit with bigger tyres and extended wheel arches. So First job I've started with is the front axle, I've stripped it out, removed all the components for the O/S end and stripped them all down, cleaned them and painted them and now I'm about to start the N/S. I'm not going to bother with a write-up of how I did it as I basically followed the youtube videos from Low Range Off-Road which are pretty decent and detailed. I found some minor differences between the video and my axle but only things like different kinds of circlips and bits missing from my axles such as wheel bearing thrust washer and a couple of gaskets. The big 50mm nuts had been bashed off with a screwdriver by some previous owner so it looks like it wasn't re-built properly. I'll post photos as I go. I'll also be asking questions as I go along as I know you nice difflocker's are very helpful people. I did start an overhaul topic before but I realised this was 7 years ago! So I thought I'd let that one rest in peace.






Rebuilding my Aisin locking wheel hubs

__________________________________
1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Fri Sep 07, 2018 7:49 am    Post subject: Reply with quote

So my first questions are as follows:

Leaf springs, do I need to get teflon pads to go between the leafs? There was nothing between the leafs when I took them apart but I've seen internet stuff saying there should be teflon pads for proper operation. If so where to I get such stuff? All the posts I read were yanks and their links were to US sites.

Kingpin shims, I have new shims for the KP's, the low range video showed two on the upper KP and two on the lower, when I removed the O/S upper and lower kinpins I only had two shims on upper and one on lower. Should I put in two and two? Before I removed all gubbings from the O/S end of the axle I swung the knuckle left and right and it has a large klunk in the centre position (straight driving) when I moved it side to side it was smooth until it reached the centre then stopped there with a clunk. Is this a sign of kingpin bearing problems?

__________________________________
1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Sun Sep 09, 2018 5:22 pm    Post subject: Reply with quote

Made some progress over the weekend. Got the parts painted for one side of the axle and gave the axle its first coat too. One of the u-bolt pads on the axle looks like its been replaced before, one pad is quite thick metal and looks original but the other is thin and has badly corroded so I've taken it off. Do I need to replace it?





I've painted the parts of the spring leafs that don't have any contact. I'm just going to put them together and coat the bare metal surfaces in hydraulic oil to hopefully prevent corrosion.



Here are pictures of the pads the u-bolts sit on, I've removed the damaged one now. Do I need to fabricate a new one??




__________________________________
1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Mon Sep 10, 2018 5:29 pm    Post subject: Reply with quote

A couple of pics of how the zuk looks right now.




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1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq
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Nightbar
Difflock Royalty


Joined: 30 Sep 2003
Odometer: 20605
Location: In a state of anticipation...


1999 Land Rover Defender

PostPosted: Tue Sep 11, 2018 3:22 am    Post subject: Reply with quote

Lovin' the garage!

Nice work though.

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The ex-Difflock Ambassador to Naples, Sir Nightbar DCJC DFS and 2 bars.

Plant a tree for the Difflock 3
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Mon Sep 17, 2018 12:14 am    Post subject: Reply with quote

So my axle re-build is coming alond nicely. But I have a question about pre-load. I've got one shim in top and one in bottom and the pre-load is 4.4lbs, will this be ok if I install power steering? The pic shows 2kg force which converted to lbs force is 4.4lbs.



__________________________________
1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Thu Oct 18, 2018 2:35 pm    Post subject: Reply with quote

My.posts are.getting doubled up for.some reason
__________________________________
1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq


Last edited by mibazza on Thu Oct 18, 2018 3:43 pm; edited 1 time in total
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Thu Oct 18, 2018 2:37 pm    Post subject: Reply with quote

Got my axle finally finished, was also busy rebuilding my 1200cc offroad/dune buggy, I think I'm going to sell that to make space in the garage for my suzuki rebuild. So anyone interested in buying a serious offroad buggy let me.know amd I'll.send you some.pics and details. Below is a photo of it before the engine went in.







__________________________________
1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq
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mibazza
Just got MTs


Joined: 13 Oct 2010
Odometer: 133
Location: Aberdeen


1992 Suzuki Samurai

PostPosted: Thu Oct 18, 2018 3:40 pm    Post subject: Reply with quote

I've picked up an Isuzu 1.7td engine mated to a Carlton gearbox recently. It came out of an SJ/Samurai, so that will be getting installed too once I get rid of the buggy and get the Zuk chassis into the shed and whip the G16a Vit engine and Sammy gearbox out. I'll get it fitted as I.need to modify engine mounts and gearstick hole to make it fit, then I'll whip it back out and refurb the chassis. I'll take pics as I go too. That will be in November now as I'm away at the mo.
__________________________________
1992 1.6 Suzuki Samurai
2010 Audi A4 2.0 TDI (170 PS) S-Line Special Edition
2014 Ford Ranger Wildtrak 3.2L Duratorq
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Brown832
Winch Assistant


Joined: 16 Jan 2011
Odometer: 85
Location: Hawick, scottish borders



PostPosted: Mon Nov 05, 2018 10:40 pm    Post subject: Reply with quote

Looks good pal. 👌🏻
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1995 Suzuki sj413 samurai
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plugspanner
Just got MTs


Joined: 24 Dec 2009
Odometer: 199
Location: somerset



PostPosted: Tue Nov 06, 2018 12:05 pm    Post subject: Reply with quote

good job there!
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