Suzuki Club UK

Hi everybody,
My name is Vedran and I live in Bosnia and Herzegovina. Over here here is no much 4x4 forums so I am hoping I can get some good advice, knowledge and help from You guys. I read thru most of topics which helped a lot. Recently I became, well not that proud owner of Samurai (Santana) long body 1.9 TD on the passenger registration ( pickup with seats on back and hardtop). The car's 2002 Year in fairly good condition, I would say that mileage on the clock (got service book) is original 60,000 Km. Body is also great for one Samurai, rust free, what I noticed is extremely poor metal protection at factory, there is no primer (at least inside), but only one thin layer of paint. When I bought it, mechanic told me that the car seems to be sitting for some time...
Now must be a catch that makes me crazy - suspect that I got gremlins along with Sami . It has a problem - noise and vibration.
First, I thought it was because of the total lack of insulation, the bed is opened without any upholstery and thin patches of bitumen cardboard in front. But it's not the reason, and here's how it manifests itself:
***Cold car (first few miles), almost no noise only slight vibrations in the range of 1500 to 2000 RPM (most notably at the end of the second and beginning of the third gear). When changing gears there is a quiet "click" when you let go of the clutch and a rattling noise under load at higher speeds (for example, when you running uphill in fourth). All mentioned is not too noisy or obvious at this state.
***Hot car (after few miles) seems like everything is starting to fall apart down there. Vibrations expand thru RPM range and are much stronger and You can hear loud "clack" while changing gears (depressing the clutch) and the rattle sound can be heard all the time, above 40 Km/h there is whistle sound (turbine like – maybe it is turbine I can not isolate it from rest of symphony). Also, I noticed short “Broom-broom” sound from back like subwoofer kick even radio blew few days after I bought the car (another Gizmos fuckup). It is important to note that when you drop the car downhill at idle any of the aforementioned cannot be heard.
Below, I'll write what I have done to solve this disease of Andalusian Frankenstein ....... without much success....
By the way, excuse my english.


What I have replaced:
***Both U joints on the third (rear) propshaft. Everything greased ie. spline where it slides laterally (it was dry and pretty much stuck). Other joints are OK according to mechanic ...
***One of the bearings in the Transfer Case, Transfer Case mounts are quite soft but no cracks.
***Wheels balanced (tires old but not that bad I would say, have to wait for spring to change it)
***Trans mount which was separated from the rubber and was just lying on the crossmember (you could push it up – pictured).



***Oil changed in Transmission, Transfer case, front and rear differential (as specified – pictured).

After all I fixed and changed, my problem is still present so I suspect that one of the propshafts are out of balance and it chewed U joint again. Sure I planned to do a balance shortly. Either that or the rear differential... now that would be a mess, think that no one around me is expert in overhaul /adjustment and swap is complicated as I can see from other topics (matching front and rear etc).
I hope that someone have deal with similar problem and help me out. Looking forward to hear from good people.
Bests to all!!!!!!!!!!

Swapping diffs is really easy, if you can find out what ratio you have. Because it's a Samurai, you should have 3.7:1 differentials, which are plentiful.

to the club.

It sounds like you have done the obvious stuff so far.

Did you pull the propshafts apart? If so did you reassemble them correctly so the joints are in line as per the first picture on the link below?

http://forum.suzukiclubuk.co.uk/vi ... =12&t=5629

If they are out of alignment that can cause vibration, and it's a simple, free fix.

Thanks for fast reply guys,
Yes, propshaft alignment was first to check. It is OK. I would suspect differential right away but one thing is true. After I changed U Joints ride feeling was really stiff and straight for few days. I went offroad and let it idle (great torque with diesel) in first speed without engaging throttle and it was really smooth and slow crowl without "catching" feel down there..? That is why I still suspect in joints maybe they were poor quality or get dry somehow or just got damaged by propshaft vibration. Back to diff: If I found one, do I swap whole axle or just diff itself, what bother me is backlash, spring adjustment and other thing connected to diff overhaul which I dont even know how to say in my language

Try putting the rear axle on axle stands and slowly turn each wheel. The other wheel should turn in the opposite direction with a standard diff, they should turn easily. Then try chocking one wheel and turning the other, this should turn the prop shaft.

Doing this you may see a loose diff pinion, indicating a diff problem or identify a failed UJ on the prop.

If you do find a diff with the right ratio, and it's in decent condition, I'd just pull the half shafts out remove the diff, then fit the replacement.

ladaman,
this is just what I needed since I didnt know how to actually check diff. I will try this on Saturday, got two good jack stands and hi-lift. By doing this, what will indicate bad diff or UJ? Some sounds or movement resistance?

Loose ujs can be checked just by physically wobbling them by hand, should be able to see / feel play in them.

Depending how badly worn a pinion bearing is you can wobble the flange on the diff. Is the diff leaking oil?

Presume it is handbrake on rear drums?

When you did the props had the coating be rubbed of the splines? If they have been used with out grease the coating might have been rubbed off and it creates "slop" in the joint.

As Jordi says, plus it should move pretty easily and smooth.

Does anybody know what the standard ratio is for diffs on a diesel Sammy? I said they would be 3.7's,but now I think about it, that's petrol sammies - I don't know how diesels differ, because we don't have any in the UK...