Putting in lower transfer case gears and really getting on the throttle can sometimes damage the front output shaft. This results in a loud popping noise under load and is detrimental to the life of the output shaft. Repeated popping of the front output shaft gear will result in gear failure and loss of power to the front axle. In 1993 Suzuki upgraded the output shaft and stopped using the older style shaft that was prone to failure. These later style shafts are a drop in replacement for 1986-1989 transfer cases. This upgrade is especially good for transfer cases that have lower than stock gearing in them because the lower the gear, the higher the toque load going through the gear. The front output gear can be installed without full disassembly of the transfer case. Only the front output cover needs to be removed to install this gear. Replace your older gear now and keep it in your tool box as a trail spare. Fits 1986-1995 Suzuki Samurai's.
Does your transfer case get stuck between gears? Is your shifter stuck and won't move? The most likely cause is a worn out shifter seat. This easy to replace item can be installed in just a few minutes.
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Do you want low gears without the hassle of rebuilding your transfer case? Let Trail-Gear install our 6.5 transfer case gear set into your 1986-1995 Suzuki Samurai transfer case. We dissemble your t-case, clean and scrub everything. We clearance the housing as needed and install our 6.5 gear set. All new bearings and seals are installed. The stock front output gear is upgraded to the later, heavy duty version to prevent front end slipping. A new shifter seat is installed for smooth shifting.
To send in your case for rebuilding, drain all the oil out of the case and remove the shift handle. Wrap the case with rags or a towel to absorb any residual oil. Then cover with at least 1 inch of bubble wrap. Place the wrapped case in to a box. Please include your full name, address, and phone number inside the box. Then place your order by calling or clicking on the shopping cart below. Ship your transfer case to us. We will install our low range gears and then we pay the return shipping to your door. Price includes a $200 core charge.