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Suzuki Samurai Transfer Case Rebuild and Shimming

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In this video I show ya'll how to shim and rebuild the transfer case on the Suzuki Samurai.
Reference Material used for Transfer Case Rebuild:
Trail Gear Instructions:
www.trail-gear.com/pdf/suzuk-t...
Suzuki Samurai Service Manual:
rover.ebay.com/rover/1/711-53...
ZuksOffroad Parts Used:
Rebuild Kit:
www.zuksoffroad.com/Samurai-t-...
Seal Kit:
www.zuksoffroad.com/Samurai-t-...
Twin Stick:
www.zuksoffroad.com/ZOR-Siames...
Brass Shifter Sheet:
www.zuksoffroad.com/ZOR-T-Bra-...
Transfer Case Cradle:
www.zuksoffroad.com/ZOR-1714-b...
Transfer Case Upgraded Mount:
www.zuksoffroad.com/ZOR-Panty-...
Tools I Used in Rebuilding the Transfer Case:
T-Handle Allen key set: amzn.to/2NtsCin
C-Clip Pliers: amzn.to/2qUbs4w
Snap Ring Pliers: amzn.to/2HNRbHq
Dead Blow Hammer: amzn.to/2qUuRm2
6' Digital Calipers: amzn.to/2HJaFgx
Permatex "The Right Stuff": amzn.to/2qUhjqv
Mobil 1 Grease: amzn.to/2HJbqpQ
Milwaukee 1/4 Ratchet: amzn.to/2qTUxin
Empire Speed Square: amzn.to/2qV0ifP
Gloves: amzn.to/2qSZGYa
If you would like to help support the channel check out ELK Motorsports Patreon Page:
/ elkmotorsports
Equipment I use to make videos with:
Panasonic G7: amzn.to/2qUrc7K
SD Card: amzn.to/2qUT8sd
SunPak Tripos: amzn.to/2r0cUTd
Rode Video Micro: amzn.to/2HNaqkC
48" Camera Slider: amzn.to/2HFGTt9
Welcome to ELK Motorsports. My name is Trey Koepsel and on this channel the content will be mainly centered around my Suzuki Samurai, La Otra. This content ranges from how to videos, DIYs, product reviews, diagnosing and repairs, as well as varying levels of fabrication. The main focus of this channel is to entertain, educate ( me as much as you), and most importantly have fun. If you enjoy fabrication, automotive modifications, and being entertained, then SUBSCRIBE to the channel to stay up to date on what I've got going on in the shop. So with that all said welcome to the channel.
Email: ELKMotorsports1@gmail.com
/ elkmotorsports1
DISCLAIMER: This video and description contains affiliate links, which means that if you click on one of the product links, ELK Motorsports receive a small commission at no extra charge to you. This helps support the channel and allows me to continue to make videos like this. Thank you for the support!
Channel Sponsors:
Zuks Offroad
Camp Verde, AZ 86322
(928) 567-3061
ZuksOffroad.com
/ zorproducts
Pro Stickers
5488 S Padre Island Dr
Corpus Christi, TX 78411
(361) 452-2840
/ emblemoverlays

Опубликовано:

23 мар 2018

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Комментарии : 187

@briandinse8632 6 лет назад

Very nice overview! Thank you for taking the time to show this and to produce such a nice quality video. I've done a few TC rebuilds now and the only thing I'd add is that folks may want to consider changing out/replacing the two detent springs and even adding the second smaller available spring that nests inside of the main detent springs. It will shift and click/hold in place with much more authority. This will also fix a transfer case that is popping out of 4-LO. They are inexpensive parts to replace and easy to do if you are already in there. I'll be watching for more excellent videos - keep up the great work!

@ELKMotorsports 6 лет назад

Thanks for the heads up, and I will.

@trackdaze446 2 года назад

Video is a few years old now but still helping! Halfway through my tcase refresh with your vid for guidance. Thanks man!

@sevensenseification 6 лет назад

Man you are a genius. I would never get this back together. Very nice work and clean like everything you build. Very nice shop do you have. I wish i had my garage like your shop.

@ELKMotorsports 6 лет назад

Off Driver I always wanted this setup at home, and when I got this house. The garage was the first place I moved into, lol

@williamhorton8989 2 года назад

Thank you very much for this video! Well done with great detail! It took all the worry out of rebuilding my 86 Sammy's case.

@jonpiper32 6 лет назад

This is one of the best vids I’ve seen on RU-vid. Subscribed

@ELKMotorsports 6 лет назад

Thank you so much for the support, hope you continue to enjoy the channel!!

@TheAlaskaCajun 3 года назад

bro I've watched this video a few times in preparation for pulling mine apart. I already did my tracker re-gear and twin stick and am about to pull the samurai transfer case out soon. Thanks for doing these videos. I noticed you haven't posted in a while, I hope all is well!

@ThemHallBoys 3 года назад

One of THE BEST rebuild vids i've ever seen on ANY subject. Thank you very much!! LET ME EDIT THAT. It would have REALLY helped if you slowed down and showed the actual orientation of the parts/bearings on the main shaft especially. I got stopped in the middle of mine and luckily i took pictures or i would have has things stacked ALL wrong.. LOL Still great vid and totally appreciate it!!

@marcinS1988 3 года назад

Love your videos man!!!! I have a 98 Samurai and it's all rusty but i love this car! Keep up the good work my friend.

@shawnh9677 6 лет назад

awesome ill be using this video this weekend on my gear install and rebuild

@genebodenberger 6 лет назад

I have a spare transfer case and I have no idea what condition it is in, so it has to come apart and be rebuilt. It sat on the ground somewhere in Nevada for a few years and sat on the ground here in Montana for a few years. This video will definitely help in the process. Thanks much. isots

@ELKMotorsports 6 лет назад

You're welcome Gene.

@odysseus9941 3 года назад

Fantastic work! Greetings from Germany

@alfakrab6134 2 месяца назад

Thanks again. That ball bearing fell out when i had it upside-down and i didn't know where it went. Between the tcase switch and the shifters

@lukskywalker834 4 года назад

Great video and workshop. During mesurments you can take thickness of Swanson, push zero button on caliper and then take depth measurment from top of Swanson all the way down to bearing housing :)

@ELKMotorsports 4 года назад

+Luk Skywalker, your right! I somethings like to do things the hard way, lol.

@Jdawg_357 4 года назад

Fantastic and informative video, will definatepy be using this thanks :)

@sebastianlloyd6746 4 года назад

thanks for the help rebuilding my Transfer case

@johndudley5987 6 лет назад

Great video Trey. Man you sure know the zuk keep um coming.

@ELKMotorsports 6 лет назад

John Dudley you got it.

@cablety Год назад

Such a helpful vid! Thanks mate

@carltonhunt8088 6 лет назад

Definitely gonna put this knowledge to use. Thanks for the video!!!!

@ELKMotorsports 6 лет назад

Carlton Hunt your very welcome

@WanderingDad 6 лет назад

I watched the math 3 times, not quite there yet. I'll keep at it. Thanks for the awesome resource.

@ELKMotorsports 6 лет назад

xHECKx no problem, it was confusing to me to at first the way they have it in the book. And then I was just looking at out on the bench and it just clicked. You'll get it, I'm sure.

@joyceano5354 3 года назад

Love the cleaning the parts bit!

@litoloco4fish 4 года назад

Incredible memory 👍🏼👍🏼

@ka4172 6 лет назад

Thank you for showing the right shimming proceed!

@ELKMotorsports 6 лет назад

ka4172 your welcome!

@ka4172 6 лет назад

Thank you sir! Whats the secret of a dual transfer case build? Sideckick Gearbox and transfer adapted on Samurai transfer?

@ka4172 6 лет назад

Maybe the mysterious "Klune box" or the double SJ (Jimny) shiftbox the Japan rock crawlers use (27:1)?

@ELKMotorsports 6 лет назад

ka4172 that's a good question, lol. I'm actually going to do more research on that subject for my buggy build.

@ka4172 5 лет назад

If you leave one shift ball between the two shift axis outside (like you show in video) you can use 2wd low with only one stick (no 2 sticks are needed) that was sharpend at front and rear.We use this at our competition Trials.

@ELKMotorsports 5 лет назад

You are correct, the two sticks just make it a little easier to navigate the transfer case. But it is totally doable to divorce the T-case and only run one shifter.

@alexandrogiraud4737 Год назад

Good job from Houston, TX

@entertainmentvlogs5158 Год назад

Awesome mahn. Love from India

@maurizioangionihbn2716 3 года назад

Molto bravo. Top.

@davidcraft4909 4 года назад

great video, but I'm learning how bad I don't want to mess with my transfer case. the front output is a little loose and the rear output is too. Neither one is really that bad but I'm watching them and I'm getting ready to fix it before it causes some major damage in the T-case. I'm not sure what it will do from being loose but I know enough to know that if you find play in something you better fix it because it will mess something up, and that applies to anything really.

@IBMara 6 лет назад

Thank you. Great video.

@ELKMotorsports 6 лет назад

Leo M. Mara your welcome

@JaOzrenRadovanovic Год назад

Great video! What ratio are those gears?

@jessebellis478 3 года назад

Y no more vids im dying to see more videos man !! Zukis for life !!

@shawnh9677 6 лет назад

quick question when you are pressing on the new bearings do you use feeler gauges to leave a certain amount of clearance or just press them down until they stop on the shafts. I dont have a service manual to check.

@ELKMotorsports 6 лет назад

You just press them on until they stop, you actually are putting spacers on all throughout the shafts as you assemble it.

@shawnh9677 6 лет назад

thanks man

@jordanp6420 6 лет назад

Very nice video, I can follow through all the disassembly but after that I get lost hahah

@ELKMotorsports 6 лет назад

Jordan P, I'm sorry, maybe I should make the scenes longer in between cuts.

@smalltown6424 5 лет назад

I like your bolt holder.... I always have drawn a picture of what I take apart on a cardboard box and punch holes in it so I don't mix up long and short bolts... Your way might be easier

@ELKMotorsports 5 лет назад

Small Town , yes, some spare peg board I had that I didn't want to throw away. That little piece actually came of a larger one. Used it to paint some hardware too.

@space6712 Год назад

Hello should I use the Permatex Ultra Grey or the Ultra Black gasket maker when putting the transfer case back together?

@aboamaar2066 2 года назад

I wish you good luck... مبدع

@suzysuzuki8865 2 года назад

Should there be play in the input shaft after the flanges are on? Replaced everything and installed 4.16 gears. Can’t remember how it was before but it has up and down movement.

@AlexandrosZisis 5 лет назад

Hello and thanks for the video! What is the liquid you use to clean the parts?

@ELKMotorsports 5 лет назад

Alexandros Zisis, it's just low odor mineral spirits.

@jokolowono3681 4 года назад

love your vid it"s boys toys !!

@bobbyallison6262 Год назад

Are all of the t case seals the same size

@josesilesgarcia9859 4 года назад

hi trey !!! How are you ??? is another day checking the sensor of the transfer case I realized that it was missing because it lacks the steel ball that makes the contact, would you know how to tell me the diameter please ??? thank you very much and excellent video as always ! very professional !! greetings from Spain !!!

@scottszuk5736 Год назад

Hi ,Is the detent ball for the 4 wheel drive selection switch the one you need to remove to install the twin stick from Zuks offroad?

@scottszuk5736 Год назад

never mind , I watched all the video

@jessebellis478 3 года назад

Zukis for life !

@19frito 2 года назад

I cannot press the detent ball down with the flat head it’s really kicking my ass, u just made seem so easy lol

@sinnakjell7077 3 года назад

Thank you. might do a Rocklobster kit to my jimny, this will def help me out, not to f it up lol

@jonathangonzalez327 6 лет назад

Awesome, Thanks!!

@ELKMotorsports 6 лет назад

Jonathan Gonzalez, your welcome.

@vincenttschida8849 6 лет назад

What size press is that? I'm hoping to the "20 ton" bottle jack press from harbor freight for the same job.

@ELKMotorsports 6 лет назад

That's what I have, I just upgraded the bottle jack to a pneumatic of the same size.

@raghavrahul3659 4 года назад

Awesome rebuild ur video was much helpful for me to repair Suzuki gypsy( long wheel base in india) transfer case, I have one issue in my vehicle fuel evaporation is more during summer season I use the vehicle occassionally I checked vehicle completely there is no leakage nothing but still with in a week fuel evaporation is more , my vehicle is powered by 1.3liter MPFI engine. Fuel evap system also works well. Within a week 3-4liters of fuel evaporates. Any suggestions pls

@ELKMotorsports 4 года назад

Raghav Rahul, that's interesting. If I had to guess I would start with the gas cap O-ring. If it is cracked or dry rotted. You could also look at the rubber fuel lines that run under the truck. Rubber, especially when it comes tio fuel, can be very porous. I know that when pool run surge tanks in the trunk of cars the rubber fuel hoses allow the fuel tio permiate out and you get the smell of fuel through out the entire vehical. You may need to upgrade the lines to a higher quality material. This could be a little bit of trial and error finding the solution tio your problem, but this is where I would start.

@raghavrahul3659 4 года назад

@@ELKMotorsports ya u were right removed the fuel tank and checked the fuel pump holder it actually had a small hole/crack on it planning to buy new fuel pump holder . Replaced the gas cap as per ur advice and replaced some of the fuel lines which wer partially ok and partially not ok.

@ArifKhan-cv4eq 3 года назад

Great video bro. Anyway, will i need to remove the gears and shafts to fix leaking gasket, oil seal and a leaking speedometer wire joint?

@ELKMotorsports 3 года назад

You will have to pull the shafts with the gears on them, but not actually remove the grears from the shaft. In the video I actually pulled everything out of the case prior to removing the gears from the shafts

@ArifKhan-cv4eq 3 года назад

@@ELKMotorsports thanks man👍

@partyshorts 2 года назад

I just got a ‘94 Samurai last week and need to do this as well. Oh boy I’m in over my head. Any advice and a push in the right direction would be greatly appreciated. I’ll be rebuilding it with my 14 almost 15 yr old son. Thanks!

@suzysuzuki8865 2 года назад

It’s not to bad. I’ve found it helpful to line stuff up as they came off and take pictures before I pull anything off.

@alfredstaude3955 6 лет назад

Perfect. Best regards

@ELKMotorsports 6 лет назад

Alfred Staude thank you for the support!

@alfredstaude3955 6 лет назад

I really like your work!

@ELKMotorsports 6 лет назад

Thanks, I try to do it right the first time, key works being TRY, lol

@alfredstaude3955 6 лет назад

10-4

@annadawson4101 2 года назад

Does it matter if the bolt holes line up on the front and rear output flange?

@ELKMotorsports 2 года назад

Only the the u-joint flanges on the slip yoke and the longer part of the drive shafts need to match

@Hackapoid18 3 года назад

Great Video, Very Helpful! What size hydraulic press did you use?

@ELKMotorsports 3 года назад

I have a 20Ton though a smaller one could do the job just fine

@Hackapoid18 3 года назад

@@ELKMotorsports Awesome thank you 👍

@adrianvilla9650 4 года назад

Hi good video, but I have a question, what size its 5 bearing?

@ELKMotorsports 4 года назад

Adrian Villa, I'll not to sure. I generally just order the rebuild kit and it comes with everything you need minus any shims you would need. And that's only because there is know why to know what you'll need until you get in there, and it helps keep costs down too.

@drewgalbreath5654 2 года назад

Very awesome video man! I don't claim to be a pro so I'm not trying to say I could do it all better 🤣 but I did think maybe itd be a little more accurate to measure to the top of the speed square, measure the thickness of the speed square, and then subtract them. Instead of eyeballing when you're at the bottom of the square. Just a thought. Again, not trying to be that guy who sits behind the keyboard and claims to know everything. Just trying to help with the little I do know. I'll also add, I'm sure the way you did it worked just fine. Lol

@alaskanadventures1164 6 лет назад

So if the cages are still fairly tight could i get a good measurement of shafts so i dont hafta wait for shipping twice? Takes a while to get to Alaska.

@ELKMotorsports 6 лет назад

AKboony stomper, unfortunately the problem with shimming lies in the gears having torque applied on them.The case(s) are all machined originally to a specific spec and the shafts are machined to a specific length. Once torque is applied things start to wear. So using the original gears can need one specific shim, while upgrading gears could need another shim. But you do have options. If there is a local machine shop they could make you the shim(s) you need so you wouldn't have to wait on shipping. Or they are fairly cheap, I want to say like $8 USD, so you could get a few when you order gears. Unfortunately it's like when you rebuild a motor, you really don't know what you need until you take it all apart. I hope this helps.

@alaskanadventures1164 6 лет назад

ELK Motorsports i have it apart & have 2 grumbly bearings & 1 sloppy needle bearing in the mainshaft. Massive metal in the fluid & the vibration got so bad i thought something was gonna explode.. Looked like brass.it has the 6.5:1 kit in it. Not a single shim made me think the previous owner didnt shim it correctly. He didn't do a lot of things correctly. Haha. So yeah...thaat's where im at. Just about to order a kit & shims but i thought i should probably install new bearings before i measure tolerance for shim size.

@ELKMotorsports 6 лет назад

AKboony stomper, YES. Absolutely, that way you don't have tio go through that again.

@alaskanadventures1164 6 лет назад

ELK Motorsports right on. Thanks for the quick reply!!! I've messed with fullsize chevys my whole life. These lil sammis...man they fit in some crazy tight spots & still light enough to stay on top of the tundra. And i freakin one-handed the trans & tcase. Lol. Not a pain to work on i cant tell ya that. Anyways-im new to these rigs & you make it simple. Thank you.

@ELKMotorsports 6 лет назад

AKboony stomper, your welcome, and thanks for checking out the videos

@amarsew172 5 лет назад

mine transfer case is producing a whistling noise. Do you have any idea what the cause of that can be

@ELKMotorsports 5 лет назад

Amar Sew sounds like it could be a bad bearing.

@huntershepherd3699 5 лет назад

I have a 1988 Suzuki Samurai 4x4 I put it in 4 low the over day and today I tried putting it into 2 wheel drive but it’s like stuck in 4 low so you have any suggestions?

@ka4172 5 лет назад

You stuck in two gears at same time,you can shift back with two big srewdriver putting in the gear and shift back both gears in neutral.

@86angrybees 4 года назад

kick the shit out of it either it will break or it will pop out 🤣

@junybeltran4920 5 лет назад

Hi elk where can I get tranfer case seal from ??

@ELKMotorsports 5 лет назад

Juny Beltran, Zuks off-road, low range off road, there is a genuine Suzuki vendor on eBay too.

@jordanp6420 6 лет назад

What liquid do you have in your parts washer?

@ELKMotorsports 6 лет назад

Jordan P, low odor mineral spirits.

@daneast 17 часов назад

If you are installing the detent ball between the shafts (keeping it stock, or using something like a Twisted TT shifter), then do NOT use the method shown in this video. It is nearly impossible to install the H/L shift fork first. Instead, install the 2/4 shift fork first, as it is much, much easier to install that spring loaded detent ball when you don't have to mess with the middle ball at the same time. The method shown in the video is really only suitable if you are not installing that center ball, like with a twin stick setup that he goes with in the video.

@EivinSukoi 6 лет назад

Very nice vid , I’ve been looking for a vid like this. I saw you didn’t torque any casing bolts , am I right ?.

@ELKMotorsports 6 лет назад

EivinSukoi, my Milwaukee 1/4" ratchet goes to 30 ft/lbs which is perfect for the case.

@EivinSukoi 6 лет назад

ELK Motorsports Thanks .

@Aguatys 5 лет назад

Excellent ¡¡¡¡

@ELKMotorsports 5 лет назад

Aguatys, thank you!!

@oc9946 3 года назад

I have a question. I have a 94 Suzuki Jimny 3 cylinder Turbo on a 2” lift with heavy black rock steely rims. The motor and turbo works harder on the take off. Does rebuilding my t-case to a 4.16:1 t-case kit help my take off? I’m really trying to stay away from doing the front and rear diff ratios.

@ELKMotorsports 3 года назад

Yes out would help. And that's what most ppl do. It's cheaper to do the t-shirt case gears than both front and rear diffs.

@oc9946 3 года назад

@@ELKMotorsports thank you so much for you’re input and content! 👌🏽

@maddawg4599 3 года назад

I have my T case out, low range 4.9:1 kit sitting beside it. This is all I need to see to know that I need to take it to someone else and let them do it lol 😳

@micklaporta4503 6 лет назад

nice job , now get that head gasket fixed and do the turbo reveiw

@ELKMotorsports 6 лет назад

mick laporta definitely

@yz125riderrr 5 лет назад

It looks like you have zero play in any of your gears. I have a new oem suzuki shaft and I put my needle cage, new low range gear, the spacer and drive gear (as seen from 13:56 to 14:14) but my low range gear has a little bit of play. Enough to worry if its normal or not? Yours looks real tight. I removed the drive gear and just put the spacer, low gear, bearing on to make sure I didn't fully press it on but there is still play if that makes sense.

@ELKMotorsports 5 лет назад

Ok, I'm going to repeat what I believe you are saying just tio make sure I'm understanding you. On your output shaft (long shaft) you put your needle bear. Then you slide the gear over it, and then you put your spacer. And then your pressing on the drive gear for the Speedo cable, and the play in the big gear is from where the shift collar shots and the drive gear? Like side to side play when the shaft is held horizontally. Right?

@yz125riderrr 5 лет назад

@@ELKMotorsports Correct. Looks like its normal as it does the same thing on my old shaft I gave it a try. I did press the drive gear on and the big gear has some play (very tiny) but I guess the shift collar is pretty wide that it grabs the gear regardless of small play. Just going to shim the case properly now. Thanks for video.

@mazokawy 4 года назад

hola amigo podria enviarte desde mexici un transfer para reparacion?? saludos desde la paz b.c.s. mexico

@dattotenga2521 9 месяцев назад

How are you can I get strating Sistine leson?ILeodegar Cosmas Tsnzania

@dattotenga2521 9 месяцев назад

From Tanzania

@karlsona100 2 года назад

what means twin stick mode

@jeremywalters9459 5 лет назад

I was trying to take disassemble the shaft that has all the big gears on it and it exploded Any idea where I could order that shaft lol

@ELKMotorsports 5 лет назад

Jeremy Walters I would check with Zuks of Hazard.

@jeremywalters9459 5 лет назад

It’s ok I found it and ordered it

@jeremywalters9459 5 лет назад

$170 ;-;

@jeremywalters9459 5 лет назад

ELK Motorsports wym?

@errolrojas3460 6 лет назад

I think you used an allen T handle right? There is no link to that tool

@ELKMotorsports 6 лет назад

Errol Rojas, what part of the video?

@ELKMotorsports 6 лет назад

Thank you for pointing that out, I just updated the Tools list. It's at the top of the "tools I us in this video" section.

@errolrojas3460 6 лет назад

Ten minute twenty three seconds I can see the grey T-Handle on your white bench.

@ELKMotorsports 6 лет назад

Errol Rojas, yeah, I linked the set. It's a mmm Allen I believe.

@robertsease2621 2 года назад

That looks hard as shit! Im gonna pass on doing that my self.

@triyiambaksinghrajawat5595 3 года назад

Hi , I am form India , owning one SJ413W , My transfer case has got little noise in while driving in 5th Gear . can you pl. suggest what could be the problem?

@ELKMotorsports 3 года назад

I had noise coming from the tunnel of my samurai at all speeds. And the first part that I rebuilt was my transmission. I replaced all the syncros and bearing. This got rid of the noise, for me. This is one of two places that the noise could be coming from. The other place would be the transfer case, that's if your hearing the coming from the tunnel inside the truck.

@triyiambaksinghrajawat5595 3 года назад

@@ELKMotorsports Mine is in Transfer case . My configuration is as below :- Engine : G13BB GearBox : 5 speed Transfer case : Stock transfer case, don't know the gear ratio. Tyre Size : F-78-15-4PR Problem Statement : while driving in 5th gear with 2 High and with Free wheeling hub in Free position ( Highway Driving ) , I am getting noise from my transfer case. Its a constant noise but intensity is low , but irritating, Can you pl. suggest what could be the problem ? and what could be the solution ? Request you to kindly help !!

@ELKMotorsports 3 года назад

@@triyiambaksinghrajawat5595 it sounds like to me your in need of a T-case rebuild, but before jumping completely into that, I would drain the fluid and check the quantity of fluid, debris like dirt/mud, and a high quantity of metal in the fluid. Also check the u-joints on all three driveshaft, and check to see if they are properly phased. All of these checks are little to no cost to you except your time. This is where I would start.

@triyiambaksinghrajawat5595 3 года назад

@@ELKMotorsports Mind telling me the success rate of the Transfer case rebuild , as here in our country its believed that T-case can not be repaired and noise of T-case cannot be removed through rebuild.

@triyiambaksinghrajawat5595 3 года назад

may I have your contact no. and suitable time in your time zone to to talk to you .

@danielnagy5721 3 года назад

If you would visit Hungary, you have as much free beer as you can drink.... :) Thanks!

@PTSix-eg4zj 5 лет назад

All fantastic except I don't mean to be critical on the measurements of the cases. You can't accurately measure with the caliper and "eyeballing" the back of the caliper body to the bottom of your straightedge...which actually could not be as straight as you think. This method can have you out a LOT more than you think. You can use the dial caliper as you have intended but you have to use the body to the top of the straight edge and subtract the difference of the thickness of your straight edge...which already mentioned needs to be machined "true" straight. That carpenter square could easily be out 0.10 before it even sits on the case halves.

@ELKMotorsports 5 лет назад

Juro Me, you are very right. This is more of a work with what you have. Most people probably wouldn't have a straight edge in there home shopbarrage. But you still have a very valid point.

@googlepleaseleavemealonean6198 4 года назад

@@ELKMotorsports So if we wanted to do this and were ordering parts/tools, what's the best way to go about this?

@ELKMotorsports 4 года назад

googlepleaseleavemealoneandstopaskingmetomakechannelsidontgiveashit, you would use all the tools I used and you would also need to get a straight edge

@googlepleaseleavemealonean6198 4 года назад

@@ELKMotorsports thanks for the quick reply! Another dumb question... Could a vice and/or sockets replace the press? Or would i need to have that/take them to the shop? Also... Im just wanting stock rebuild. Thoughts on ordering shims? Order some of each size? How many? Thanks Trey

@ELKMotorsports 4 года назад

googlepleaseleavemealoneandstopaskingmetomakechannelsidontgiveashit, a vise and socket won't cut it. You with need a press and I ordered the shims after I took my measurements. I suppose you could could get them before hand, but you may need a combination of different or possibly the same size shims. It would be cheaper to just order them after you know your measurements.

@BigSkyMobileRV 4 года назад

Are you from camp Verde Arizona?

@ELKMotorsports 4 года назад

No, I'm from Texas. Currently in corpus Christi

@chevyscrounger 6 лет назад

Timing for this video couldn’t have been better. My new gears are out for delivery right now.

@ELKMotorsports 6 лет назад

Awesome, Just to note, if they are larger gears you may need to grind a bit off the inside of the case to clear those larger gears. the trail gear instructions show this, but after you have all the gears and bearing pressed back on the shafts and have everything about ready to go back together. Just test fit the gears inside and check where you may have to do some clearing.

@chevyscrounger 6 лет назад

ELK Motorsports yeah I ordered a new set of trail tough 4.16 gears using the 20% coupon on eBay. For $300 I couldn’t pass them up. I’ll be sure to check for contact points when I go together with it all.

@ELKMotorsports 6 лет назад

That's a sweet Deal!

@chevyscrounger 6 лет назад

I have measured my case and my measurements are spot on with yours. I haven’t got the gear clusters together yet so I haven’t measured those yet. I had 1 shim on the output shaft. Did you cut your parts washer shelf down?

@ELKMotorsports 6 лет назад

Rich Miller yeah, I didn't like how it took more than half the opening. I would have had to remove it all together to get the cases in and out of it. I just re bent the lip on it and it was strong again. And you'll need to get those shafts together to know how much to shim, but it sounds like it's going good.

@jeremywalters9459 5 лет назад

At 9:48 when you took the last gears out you literally did it on accident and mine won’t even budge i used a maker for hours and nothing worked, any ideas?

@ELKMotorsports 5 лет назад

your supposed to use a plastic/ deadblow hammer to remove the rear output shaft from the center/rear case, which ever it sticks to. you could also use a brass mallet if its being stubborn

@jeremywalters9459 5 лет назад

ELK Motorsports I was using a rubber mallet for hours but it like stuck, is there something I was supposed to remove? There was a screw there and another set of directions told me to remove the speedometer sensor this but I can’t tell if I already removed it or if it just won’t budge

@ELKMotorsports 5 лет назад

Jeremy Walters yes the Speedo gear should be completely removed

@jeremywalters9459 5 лет назад

ELK Motorsports any tips on how to remove it? Because it isn’t budging and all I’m doing is scratching the metal

@ELKMotorsports 5 лет назад

Check 5:21

@davidcraft4909 4 года назад

you should of just said you're using permatex righstuff because its the right stuff, lol.

@aintskairtolskol9520 Год назад

i guess metric system is all that is left in the world, now i remember what it is about your vids i dont care for

@suzysuzuki8865 9 месяцев назад

You’re watching a video about a vehicle that was made and designed in a country that uses metric?

@davidheinrich174 4 года назад

"you have to go to the 0.00 of a millimeter"...I'll just eye-ball it

@ELKMotorsports 4 года назад

David Heinrich, yup. I'm guessing y'all didn't know I have a bionic left eye with the upgraded machinist HUD.

@daneast День назад

Great video, but you didn't show how you removed the smallest set of needle bearings that are in the inside of the shaft. I used the bread technique. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-b0rVQP7F6FI.html

@rizzoyo8557 5 лет назад

are you rebuilding it or making love to it...can't tell.

@ELKMotorsports 5 лет назад

Michael Rowe I think it's a little bit of both

@MonkeyWithAWrench 5 лет назад

not gonna lie, i actually cringed when i saw you use the DA sander to clean the gasket surfaces and the tap in the drill to chase the threads. dont do that. your measurement techniques were ok-ish, depth mics would have been the correct way, but i get it, they can be pricey. get some more accurate tools. those calipers are not accurate at all. dont mess with digital calipers unless you spens some real money on them. as the battery voltage drops the measurements change. some SPI analog calipers are not expensive and make those harbor freight calipers look like a joke. get a real straight edge, those speed squares are NOT flat or straight enough for tight tolerance. but other than that, you assembly techniques were pretty good.

@ELKMotorsports 5 лет назад

MonkeyWithAWrench, thanks. And appreciate the input. Your correct too the correct tools to do this job the right way, are very expensive. This was just my way of showing guys how you could do it with what you've got laying around the garage. But the point you make is valid, this is not the professional way.

@ELKMotorsports 5 лет назад

What brand calipers would you recommend?

@MonkeyWithAWrench 5 лет назад

@@ELKMotorsports the brand is SPI. they are not starret quality, but are leaps and bounds beyond harbor freight while still being fairly cheap. expect to spend around 60 bucks. they will be accurate enough for the stuff you're gonna be working on. DO NOT get digital calipers. learn to read analog dial calipers. they are more accurate (at least in the price range we are talking) and have many other advantages. you can look at MSC dot com for them.