therealprotaco's 3rd Gen Towed Suzuki Samurai Crawler

Aw man now I want a samurai more! It is nice not having in the back of your mind (newer vehicle, electrical, need it to get around)

Vs yeah im.gonna pull it and see what is going on make a run order some parts flex it and make sure it is good

 

I have absolutely been pulled out from being stuck by a Samurai. Things are sick. I was pretty jealous tbh

 

I will say that with the 6.5:1 low range in the t-case the torque is insane. I could totally see it pulling out a stuck taco. Recovery points on the rear are way lacking though. A rear bumper (probably an I Beam with some shackle mounts and brackets welded on....) is high on the list.

 

How does the taco do in flat-towing the samurai? I’ve gone back n forth between this or a YJ lol.

 

It does great but I have 5.29s. I would not want to pull it uphill in the mountains without the re-gear. The stock brakes are fine and don't seem to have any issues uphill, downhill, or otherwise.

 

Well, looks like the damage to the T case was much worse than I thought!



I already have a new (used) stock t case in there for mock up purposes and a new (used) back housing on it’s way to swap my 6.5:1 guts into so not a huge deal.

This is a BIG install weekend for the samurai though. This weekend I’ll be installing:

1. Jeep YJ Spring Swap Kit w/new YJ Springs
2. Stage 2 Over The Top Steering Kit
3. New Rear Brake Proportioning Valve (mine has a small leak)
4. New Skid Plate

Unfortunately the back housing and shims didn’t show up for the T-Case rebuild so that will have to wait. I may or may not need driveshafts too. Fun fun fun!!

 

Pshh! A little duct tape and she'll be mint!

 

Nice combo! I share the love for the samurai’s...Great thread.

 

Thanks!

So left the office less than 2 hours ago, stopped at ace to get some drill bits, drove home about 20 minutes....and now it’s only 5:15 and here we are:



Not that I’m complaining....but that shouldn’t have come apart that easily!!!

 

Well that was a hell of a weekend!



Also, the trans mount didn’t get delivered on time and the frame needs a notch to run a front driveshaft. The rear driveshaft angle is crazy too so a new set of front and rear driveshafts are getting ordered too...

 

Hell of a Sunday Funday working on the Samurai again! Took 4 transfer case back halves to get one that wasn’t cracked or had totally stripped out threads. Was able to rebuild the T case and now it’s sitting on the floor waiting for the paint to dry on my 2nd new t case cradle.

Was a fun rebuild. Had to clearance the new back half to fit the giant gears for the 6.5:1 low range.



Also got the extended front upper shock mounts installed. Should have PLENTY of shock travel now! Limiting factor will almost definitely be the fenders.




Next steps are to cut the the trans crossmember and weld in the crossmember notch plate, install the t case in the new cradle, install that cradle assembly in the Zuk, and wait for driveshafts to arrive!

 

Rebuilt T-Case and new T-Case cradle went in last night as well as the stock rear driveshaft. Not only did she move, but she moved with no vibrations at all! Driveshafts should be delivered tonight and trans crossmember is getting notched this weekend. Then she can go out for a shakedown!

New T-Case Cradle -- if this thing can't keep the t-case in one piece then I give up!



Here's how she sits as of today:



I do also have an HD tie rod to replace the bent one that's in there now. Just need to ream out the knuckles first for the huge full size Chevy tie rod ends.

 

You make me want a samurai more than I did before

 

Do it! The best part is I'm still into it for under 10k even with a full new suspension and everything else I've done. I also just ordered a new Toyota 3k carburetor and swap kit to get rid of the insane birds-nest of wiring and vacuum lines that run the ECU controlled, untuneable stock carb.

 

I'd love to. But that is not in the cards for my life right now. In 3 years it very well could be.

That being said when you take it off road and push it real hard show us some pictures! AZ has some fantastic spots to put it through the paces

 

Will do! The plan is a shakedown run next weekend and then get her out for some crawling!

 

So close!

Driveshafts are here, tow bar installed in the frame extension brackets that the YJ spring shackles mount to, and the crossmember gets notched tomorrow!

Just need to bleed the brakes, set up the new high misalignment heim joints on the tie rod (decided against messing with the taper reamer and full size truck tie rod ends), and set the toe. The normal tie rod ends won’t fit on the OTT steering arm but it should clear fine with an inch of spacer under the heims. You can see the tie rod literally sitting on the springs here:



I think a hitch extension is also in order here for a little better clearance with the flip up license plate on the @SOS CONCEPTS high clearance bumper. It does clear when fully turned though. Any more of a turn and the samurai bumper is hitting the truck!




@ovrlndkull

 

That's pretty cool!!! Is there a way to run the Samuri's taillights to your plug?

 

Yup, that’s what this birdsnest is for. It was already in that location when I got the samurai but I connected a new 4 pin on the other side with a dust cover since it is powered when the Samurai’s own lights are on. You also have to disconnect the battery in the Zuk when towing with the lighting hooked up this way but it’s working out great!



Got a ton of work done today too. All it NEEDS to get out there and wheel is a brake bleed.