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samurai gear installation

Samurai Transfer Case Front Output Shaft


samurai transfer case output shaft

Samurai Transfer Case Front Output Shaft

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 Samurai transfer cases. This upgrade is especially good for Samurai 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.

You can order this kit on its own for self-installation. Or you can order it with our rebuilt Samurai transfer cases and we will install it for you at the time of our installation and rebuild.

Samurai Transfer Case Heavy Duty Output Shaft
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Front HD Output gear kit
for self-installation
Front HD Output gear to be installed into
a Rocky Road transfer case:
Please order transfer case above, 4.16 or 6.5 gearing.