STC-UO_Samurai Updated Transfer Case Front Output Shaft
Contents
1. 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD step 63 step 64 slide the boot back into place Reposition the boot retainer step 65 Place the shifter in 4H Note This is done so the flange nut can be torqued more easily TELS Al sAd l IA Fes 1195 5 1680 W WIULW LOWRANGEOFFROAD COM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD Installing the Front Drive Shaft Assembly Step 66 otep 67 Install the washer and flange nut Torque the flange nut 80 to 108 ft Ibs Note We recommend using a new flange nut if possible Click HERE to purchase a new flange nut from Low Range Off Road a Step 68 Tech Tip 68 Stake the nut collar using a hammer and Flange nut properly staked punch in 2 locations TELS RA s H p Pec 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD step 69 Step 70 Position the front of the drive shaft on the front differential flange and install the Connect the other end of the drive shaft to the transfer case output flange 4 bolts lock washers and nuts Tighten the nuts 17 to 21 5 ft Ibs Tighten the nuts 17 to 21 5 ft Ibs Note Be sure to reinstall the drive line spacer if removed earlier TELS kaka sAd l IA Fes 1195 5 1680 W WIULW LOWRANGEOFFROAD COM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD Refilling and Final Te2. replaced Note Some have found success with filing the groove and getting it close to its original shape This can only be done if the damage is minor Q Step 49 Push the shifter back up out of the way for now IAS 1195 5 1680 W OFF ROAD Orem UT 84058 USA TELL Aal i Installing the Front Housing step 50 Wipe the mating surface of the center housing with a cloth Be sure this area is free of any dirt grit old gasket gasket sealer etc step 52 Place a new gasket on the front housing Insure that the gasket is aligned with the 2 alignment pins and that the holes in the gasket align with the holes in the housing dee Ei hed d WWU LOWRANIGEOFFROAD COl Phone 801 805 6644 step 51 Place a small amount of wheel bearing grease on the pilot bearing surface of the output shaft step 53 Install the front housing on the middle housing Be sure the shifter rods are properly positioned in the support holes and that the output shaft fits into pilot bearing IAS 1195 5 1680 W OFF ROAD Orem UT 84058 USA Continue installing the front housing step 55 until it fits against the center housing Install and hand tighten the 7 front mm should be no gap between the housing bolts making sure the bolts are OUSINGS located in their original locations See Caution Do NOT force these two parts NER ELIE together If they do not go together easily remove
3. IAS 1195 5 1680 W Orem UT 84058 USA TLS RAI mee Ei ged d WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 step 21 Inspect the output shaft bearing by rotating output shaft and flange It should turn smoothly with no binding It should not allow the shaft to move up and down or in and out If any problems including looseness is felt the bearing will need replacing We will show you when and how this is done later step 22 Inspect the part of the output shaft that fit inside the pilot bearing Even though we will be replacing this shaft if the old shaft shown here has discoloration scoring or wear of any kind you should replace the pilot bearing along with the output shaft OFF ROAD NE 1195 5 1680 W Orem UT 84058 USA TELL Aal r dee E J ied d WWW LOWRANGEOFFROAD CO M Phone 801 805 6644 OFF ROAD Front Output Shaft Parts Output DN Output Shaft x A Shaft Seal pr 2 op E a Output N gt J Flange Wie eee LER E Output Shaft ne I SING be NE Pilot Bearing dl D AOS Y Output Shaft Output Bearing Flange Nut Output Shaft Snap Ring TAA dee A S ad EE 1195 S 1680 W Orem UT 84058 USA WWW LOWRANGEOFFROAD COM Phone 801 805 6644 Remove the front housing gasket This gasket will need to be replaced Itisa specified thickness that maintains specified tolerances inside the transfer case and should not be substituted with si
4. Instructions Created by an Automotive Service Excellence Samurai Updated Transfer Case Front Output Shaft SKU STC UO OFF ROAD Installation Instructions Suggested Tools Brake Cleaner e Scotch Brite Pad or Fine Emory Cloth I l Twin Post Lift or Floor Jack and 4 Jack stands CAUTION Safety glasses should be 2 12 mm Box End Wrenches wer all Bui re le with 3 8 Drive Deep Socket 12mm vehicles and related tools an e 3 8 Drive Torque Wrench eq tip ment e 1 2 Drive Torque Wrench gj r e 1 2 Drive Sockets 12 24 amp 27mm e Impact Wrench 1 2 drive Optional 1 2 Drive Impact Socket 27mm Optional e Dead Blow Hammer e Small Sledge Hammer Gear Puller 3 Jaw 2 Jaw Would Work e Socket and Ratchet to fit Gear Puller e Seal Puller or Larger Standard Screwdriver e Wheel Bearing Grease td e Square Nose Cold Chisel or Punch Bearing Grease FOR ADDITIONAL COPIES OF THESE e 80 W 90 Gear Oil AND OTHER INSTRUCTIONS GO TO e Magnetic Pickup Tool Magnet on a stick www lowrangeoffroad and click on the INSTRUCTIONS tab TLL LG Fsju iB JG 1195 5 1680 W WWW LOWRANGEOFFROAD COM Phone 801 805 6644 Orem UT 84058 USA Lifting and Supporting the Vehicle Lifting Option 1 OFF RGAD Lift and support the vehicle on a twin post lift CAUTION Always follow the safety guidelines associated with the lift you are using Left chass
5. Output Seal step 34 Tech Tip 34 Position the new seal as shown The garter spring goes down or toward the fluid being sealed Note This seal is not supplied with the front output shaft Click HERE for this seal and many other transfer case parts Chamfer The seal is properly installed when it is Tap the seal into place using a hammer just below the chamfer Note The seal must be driven in evenly It may be helpful to use a socket that is a little smaller than the outside diameter of the seal Place the socket on the seal and tap the socket driving the seal into place TELS Kl elg tal p PE 1195 5 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Installing the Front Output Shaft Step 36 Step 37 Clean the output shaft using a good Place the front output shaft through the bearing as shown here degreasing solvent such as brake I cleaner or something similar step 38 Step 39 Place an 18 mm standard socket over then strike the socket sharply using the shaft to protect it and support the a dead blow hammer driving the input front housing in yourhand shaft into the bearing Continue striking the socket and shaft until the shaft is seated all the way into the bearing TELS Jed Ad s H p Pec 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA on k Ea AST j r Ra i SS es gt 3 Bearing in
6. box end wrenches using two 12mm box end wrenches See Figure A Note It is helpful to place the transfer case shifter in 2H position so you can rotate the shaft allowing easier access to the remaining bolts vt Till Y i f sjfrfsja M i AE FE 1195 S 1680 W WWU LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA s m Im L bain i 14 x AR lay 7 4 i ri d A i re aes Pol Step 5 Step 6 It may be necessary to tap the drive Remove the drive shaft and set it aside shaft using a hammer to jar it free from the differential flange TELS Jed Ad lf dd A IA A Fes 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD Shifter Parts a Shifter Lever Boot SS gt Shifter Lever 97777 Boot Retainer x I T Shifter Lever IE om Eoin Shifter Lever a Shifter Lever Shifter Lever Spring Ball JUU et heli fi Ly EE WWW LOWRANGEOFFROAD COM Phone 801 805 6644 era Orem UT 84058 USA WWW LOW RANGEOFFROAD COM Disconnecting The Shifter Step 7 Release the boot retainer by pushing the 2 tabs together and slide the boot up the shifter lever d 4 m 4 a 3 en s j E g f Ca WW ald i ONI CY m n P kif eu j Fe _ y Ge ds j K a AS l ar X i in gt or 9 Pr eg OM P wal Y gt gt atl Illustration showing shift lever guide removal
7. click HERE Or you could continue to the next step TLS RAI mee Ei ged d WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 step 42 Turn the bushing upside down align the 2 grooves in the bushing with the 2 pins in the housing and install the bushing on the pins IAS 1195 S 1680 W Orem UT 84058 USA step 43 Tech Tip 43 Rotate the bushing using the pins as a This shows the shifter bushing properly pivot 180 or until the bushing drops installed into place TELS Jed Ad lf dd A IA A Pec 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Installing the Front Output Flange step 44 step 45 Apply some grease to the seal surface Install the flange on the output shaft of the flange Note This is to lubricate the seal step 46 Leave the washer and nut off for now TELS Mal Ad hi Ld i PE 1195 5 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA TELL Aal i WWU LOWRANIGEOFFROAD COl Phone 801 805 6644 Installing the Shifter Lever step 47 Clean and inspect the shifter ball It should be uniformly rounded with no flat spots or scoring step 48 If the shifter is being reused clean the ball area with a Scotch Bright pad or some very fine emery cloth gee Ei ted Ey Step 47 Continued The sides of both grooves should be straight with no wear If wear is observed the shifter lever should be
8. he 4Wheel drive indicator switch using a 21mm open or adjustable end wrench 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Removing the Front Housing OFF ROAD step 14 Place the transfer case in 4H and remove the front output flange nut using a 2 mm socket and breaker bar Be sure to turn the nut in a counter clockwise direction Note It may be necessary to hit the breaker bar with a hammer to get the nut to break loose Tech Tip 14 If you have a 1 2 drive impact wrench electric or pneumatic and a 27mm impact socket this works very well step 15 Remove the output flange nut TELS Jed Ad F js iD Fes step 16 Remove the output flange washer 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA step 17 Remove the 7 front housing bolts using a 12mm box end wrench or socket Note There are 3 different length bolts holding this housing on Be sure to note their location so they can be reinstalled in the correct locations step 19 Remove the front housing and set it aside step 18 Jar the front output housing loose by tapping it with a dead blow hammer on the tab as shown here step 20 Inspect the output shaft pilot bearing If it is scored discolored blue or brown or has cage damage it should be replaced Click HERE for this bearing and many other transfer case parts OFF ROAD
9. is frame Front left tire Rear left tire Front Support Location Rear Support Location Lifting Option 2 We used a twin post lift for these instructions but this job could also be done with a floor jack and 4 safety stands IN Rear tire Safety stand EE 1195 5 1680 W WWW LOWRANGEOFFROAD CONM Phone 801 805 6644 Orem UT 84058 USA Na f j sd A A OFF ROAD Tech Tip Step 1 When working on suspension brakes or Position a drain pan under the transfer drive train parts it is a good idea to case spray all fasteners with penetrating oil before removal We recommend a day ahead if possible If not done a day ahead an hour or even minutes before is helpful otep 2 Remove the drain plug using a 24mm socket After the oil has drained reinstall the drain plug and tighten 13 5 to 20 ft Ibs sr HIV sAd l IAA Fc 1195 S 1680 W WWW LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA Removing The Drive Shaft OFF ROAD Front Driveline Zt om EN _ Transfer AS LAS g Case a AD NG Pan EAn pp k NM gt SSN JH er P f he O To Front SH ai Differential oY N me OJ o r Lock Washer Nut A oN Ab fa Os i A SE i Step 3 Step 4 Disconnect the other end of the drive Disconnect the front drive shaft at the shaft by removing the 4 bolts using two transfer case by removing all 4 bolts 12 mm
10. licone gasket maker or sealer of any Kind Click HERE for this gasket and many other transfer case parts Remove the output flange by striking it with a dead blow or brass hammer as shown If this method is unsuccessful see the next step Inspect Here Inspect the front output housing where the shifter rods are positioned If there is excessive wear the front output housing will need replacing Skip this step if the flange came off in the previous step If the flange did not come off in the previous step you will need to use a three jaw puller as shown here IAS 1195 5 1680 W Orem UT 84058 USA TLS RAI mee Ei ged d WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 OFF ROAD step 27 step 28 Remove the flange Inspect the flange seal surface for grooving Note If you can feel a groove with your finger nail you may need to replace this part Tech Tip 28 A Tech Tip 28 B This is the hub sealing surface after being cleaned with a Scotch Bright pad Notice the groove is no longer visable See Step 28 This flange is reusable Some flange seal surfaces can be improved by cleaning them with a scotch Bright pad TELS Jed Ad F js iD Fc 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Removing the Front Output Shaft OFF ROAD step 29 Tech Tip 29 Support the front housing in one hand If the output shaft will not come
11. out and strike sharply the front output shaft using a dead blow hammer it may be with a dead blow hammer It will take necessary to use a small sledge several sharp blows to remove the shaft hammer This is okay here because we are replacing the shaft You would not want to strike this shaft with a hard hammer if you wanted to reuse the shaft Using a hard hammer damages the threads and the flange nut will not reinstall Caution Be sure to wear Safety Glasses Pry Here gt Step 30 Step 31 Continue pounding until the shaft comes Remove the output shaft seal using a seal puller or large standard out of the housing screwdriver UMP Kal ri hd Lhd p IAS 1195 5 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Step 32 If the bearing is good skip this step If the bearing was determined to be bad now is the time to replace it Remove the snap ring press the bearing out in the direction of the snap ring groove press in the new bearing and reinstall the snap ring When pressing in a new bearing be sure to press against the outside bearing race TELS Jed Ad lf dd A IA A Pec OFF ROAD step 33 Clean the seal chamfered surface using a standard screwdriver or putty knife to make sure the seal slides into place easily Caution Do not gouge the aluminum 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Installing the Front
12. procedure TELL Aal i Phone 801 805 6644 OFF ROAD Step 8 Disconnect the shifter lever by depressing the shifter retainer and turning it counter clockwise See Figure B Step 9 Disconnect the shifter lever from the transfer case by pulling up on the shifter lever 1195 5 1680 W Orem UT 84058 USA OFF ROAD step 10 Position the shifter lever up out of the way as shown here IULI AN f WsT Tia e a Fc 1195 S 1680 W WWW LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA Transfer Case Parts Front Shifter ung Center Bushing Housing Front Housing Front Housing Bolts ea 4 Wheel Drive NE 600 m Switch Ball G DP B sj II tee hs Pa WWW LOWRANGEOFFROAD COM Phone 801 805 6644 OFF ROAD Rear Housing A N JJ Check and ha Fill Plug 1 mA Drain Plug 4 Wheel Drive Switch EE 1195 S 1680 W Orem UT 84058 USA OFF ROAD Removing the 4Wheel Drive Indicator Switch Assembly step 11 Disconnect the 4wheel drive indicator wire Simply lift UP on the tab and pull the connector halves apart step 13 Remove the four wheel drive switch ball using a small magnet pickup tool or small magnetic screwdriver Caution Failure to remove this ball at this point in the procedures may result in loosing the ball down inside the transfer case when the front housing is removed sr HIP i dd l IA ec step 12 Remove t
13. re specialized skills such as metal fabrication welding and mechanical trouble shooting If you have any questions or are unsure about how to proceed please contact our shop at 801 805 6644 or seek help from a competent fabricator Using fabrication tools such as welders torches and grinders can cause serious bodily harm and death Please operate equipment carefully and observe proper safety procedures Rock crawling and off road driving are inherently dangerous activities Some modifications will adversely affect the on road handling characteristics of your vehicle All products sold by Low Range Off Road are sold for off road use only Any other use or application is the responsibility of the purchaser and or user Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty Modification of your vehicle may create dangerous conditions which could cause roll overs resulting in serious bodily injury or death Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use Revised 06 21 13 Copyright 2013 Low Range Off Road LC All Rights Reserved TELS kaka F js iD Fes 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA
14. staller A 09913 76010 Tech Tip 39 A The Suzuki Samurai service manual recommends what is shown above as an alternative way of installing the front output shaft into the bearing You could substitute tool A with a 1 2 driver 18 mm standard socket See Figure C TLL hed hen Fsig siap Pe OFF ROAD Tech Tip 39 B Using a flash light look down between the teeth and the front housing to see that the shaft is all the way in 1195 5 1680 W WWW LOWRANGEOFFROAD CO M Phone 801 805 6644 Orem UT 84058 USA Installing the Shifter Bushing step 40 Remove and inspect the shifter bushing It should be pliable and not cracked hardened or damaged in any way If it is damaged it should be replaced Fora replacement part click HERE If the shifter bushing is in good shape reinstall it Important Notice Even if the shifter bushing appears to be in good shape we recommend replacing it with one of our upgraded Nylatron shifter bushings Especially if you are experiencing looseness in your transfer case shifter This looseness is common in many Suzuki Samurais This newly designed part is guaranteed to solve part and perhaps even all the loose shifter problem Installing the LROR Nylatron Shifter Bushing If you are not replacing the shifter bushing skip to the next section step 41 Wipe the shifter bushing area clean Note To see a YouTube Video of how to install this shifter bushing
15. sting Step 71 Step 72 een i check and fill plug using a Add 80W90 Gear Oil until fluid begins to mm socket run out and quickly reinstall the plug Tighten the plug 13 5 to 20 ft Ibs See a E E Eee ENN installed and tight Transfer Case Oil IR ers Oil capacity 1 7 1 4 USAmp pt TEE Gear oil SAE 80W 90 yP 75W 80 or 75W 90 OU filer 8 Step 73 evel plug Mass ara un i Shift the transfer case into all positions Oil drain plug 135 200 wt to insure smooth operation 18 28 N m 1 8 28 kg m 13 5 20 0 ib ft TELS Al sAd l IAA Fc 1195 5 1680 W WIULW LOWRANGEOFFROAD COM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD Congratulations You have successfully installed a front output shaft on a Suzuki Samurai transfer case We sincerely hope these instructions have been helpful If you have suggestions on how we could improve our instructions or products please email US at sales Qlowranceoffroad com TLL LE Fsig siap Pes 1195 S 1680 W WWW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD As always If you experience any difficulty during the installation of this product please contact Low Range Off Road Technical Support at 801 805 6644 M F 7 30am 5 30pm MST Thank you for purchasing from Low Range Off Road These instructions are designed as a general installation guide Installation of many Low Range Off Road products requi
16. the front housing and check for obstructions Medium Bolts Short Bolts EN Bolts Tech Tip 55 step 56 Torque the bolts in an increasingly Bo ene eee ent tighter criss cross pattern until 9 5 to 16 5 ft lbs is reached TELS kaka F js iD Fc 1195 S 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Installing the 4Wheel Drive Indicator Assembly OFF ROAD step 57 step 58 Install the 4Wheel drive indicator ball Install and tighten the 4Wheel drive indicator switch otep 59 Plug in the 4Wheel drive indicator connector Note 1 Push the coupler halves together until they snaps onto place Note 2 Be sure the wires are routed properly and secure TELS kaka F js iD ec 1195 5 1680 W WIUW LOWRANGEOFFROAD LCOM Phone 801 805 6644 Orem UT 84058 USA Installing the Shifter Lever OFF ROAD step 60 Install the shifter lever Be sure to align the grooves of the ball with the pins in the housing and the lower shift lever with the shifting rods Note It may take a bit of work to get the lever to align with the shifter rods Be patient but persistent It will go into place Step 61 Step 62 press down on the shift lever Slide the spring down into place and retainer and lock it into place by rotating position the shift lever retainer grooves with the pins inside the front housing It clockwise and a VT ofa ond Liked ID gt a
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