New SJ416 Samurai Owner

[Ladaman]

Hi guys, the crownwheel has 41 teeth..

If you get desperate I have two set of gears I removed from my Samurai when I lowered the ratio.

They are the original Samurai ratio of 3.727:1 (41/11)

I still have the bearings if you wanted to save a few quid. You'd then just need a crush collar and seal.

But see what turns up re a full, decent diff.

[deanbayley]

How much for a pair and did you keep them seperate.. Front crown with front pinion etc..

Dean.

[deanbayley]

Been on the phone to Suzuki trying to order crush collar and seal and they don't have a part no for the seal, the one on the SJ Axle thread isn't valid anymore apparently and they said its too old to come up on the parts system, they emailed Suzuki to ask for a diagram..

Decided to crack on with the strip down as I can't get bits for a few days yet anyway..

engine out.jpg (325.06 KiB) Viewed 6592 times

Also removed most of the interior and found some not so solid bits

OSR Boot.jpg (383.84 KiB) Viewed 6592 times

The seams in the corners behind the front seats look pretty much the same, will all be cut out and re built tomorrow..

On a better note the chassis is rock solid..

chassis rail.jpg (261.81 KiB) Viewed 6592 times

Worst hole is the one i already knew about.

NSF Wing.jpg (282.57 KiB) Viewed 6592 times

How has anyone ever put a BARE SJ body on its side on some old tyres etc to be welded?

Tomorrows plan is remove every piece of trim, screw, nut, bolt, wire, pipe, everything from the chassis and body so everything is restored to as new..

I want to make sure daft things like the sticky choke, really hard to move hot/cold valve, frayed throttle cable etc all work perfectly when it goes back together..

Hopefully by the end of this week it'll be ready to paint, fingers crossed.

[ScottieJ]

I haven't had a chance to look through my diffs yet for you sorry.

As for the seal part number of you could let us know the new one that would be appreciated so I can update the thread.

As for tipping the body onto its side....I do it all the time





I can easily flip an Sj tub on its side on my own, they are nice and light.

[deanbayley]

Wow i knew they wouldn't be that heavy but i thought it'd be a 4 man job, yeah i'll make sure i update you, i used your diagram to order from

What do you usually use to coat the chassis and bottom?

[Ladaman]

Been on the phone to Suzuki trying to order crush collar and seal and they don't have a part no for the seal, the one on the SJ Axle thread isn't valid anymore apparently and they said its too old to come up on the parts system, they emailed Suzuki to ask for a diagram..

Have a look on Jimnybits.co.uk http://www.jimnybits.co.uk/shop/sj-/-sa ... t_182.html
It says crush collars are out of stock, but you can get a diff refurb kit. http://www.jimnybits.co.uk/shop/sj-/-sa ... d_630.html

[ScottieJ]

You can lift a tub off the chassis with 2, but I would recommend 3or4 to avoid struggling. Or if you have an engine hoist you can put a long strap around the sills through the bung holes in the floor and the a point to the seatbelt mounts on the transmission tunnel and lift it off carefully, then roll the chassis out from underneath, best done with 2 people.

[deanbayley]

Anyone got any idea which alternator fits the 1.6 with the custom engine mounts (not sure who made them) the current 50A alternator is about 5-6mm from the mount, also what is a skinny starter?

[zook123]

Was this Sammy the one that came from Alton?

[deanbayley]

This came from Plymouth, now lives in Stockton-on-Tees (370 miles north)