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1987 Sammi

I pulled the Sammi out of the shed so I had more room on the passenger side, drilled out the spot welds on the trim bracket. Looks about like the driver side, no through rust but the surface rust has weakened the structural integrity of the rockers. I had originally planned to cut the homebrew nerf bars off and build new rocker guard/sliders that bolted on, now though I am thinking about cutting the rockers out and welding in some better steel... maybe a mini boatside to it.

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I had not planned on keeping the original shocks, but I definitely need new ones lol
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I have the week after Thanksgiving off and am hoping to spend most of it working on the sammi, plan is to rebuild the transfer case and axles. I already have chromoly shafts for the front and will be ordering chromoly rear shafts tomorrow.
 
No work getting done, but I am ordering more stuff for it.

The other day I ordered a factory service manual for it, yesterday was lights and stuff for the new rear bumper and turn signal stuff, today I ordered the chromoly rear shafts with quick change bearings/retainers and seals.
 
warrpath4x4 said:
I pulled the Sammi out of the shed so I had more room on the passenger side, drilled out the spot welds on the trim bracket. Looks about like the driver side, no through rust but the surface rust has weakened the structural integrity of the rockers. I had originally planned to cut the homebrew nerf bars off and build new rocker guard/sliders that bolted on, now though I am thinking about cutting the rockers out and welding in some better steel... maybe a mini boatside to it.



I had not planned on keeping the original shocks, but I definitely need new ones lol
Xw6eFEP.jpg


I have the week after Thanksgiving off and am hoping to spend most of it working on the sammi, plan is to rebuild the transfer case and axles. I already have chromoly shafts for the front and will be ordering chromoly rear shafts tomorrow.
Click to expand...


Cracked shock tower?
 
Sunday morning the kid and I got up early and drove 2.5 hours to go pick up some doors and a windshield frame for the sammi, unfortunately the guy sold the windshield frame before I got there.

Not bad for $60 for both doors, way better shape than my current ones
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visited with the locals while we were there also
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Not working on the Sammi for 2 weeks getting ready for thanksgiving, here's the new dining room table my son and I built Saturday, wouldn't say its "professional" quality and I'm already thinking about building a new top for it when I have more time and A) fixing a few mistakes I learned along the way and B) using better lumber than home depot lol. but its ready for the holiday season.

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finished up the front turn signals tonight, just went simple.

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3/4" LED lights

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Even works with my jacked up fender lol

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Changed out the turn signal flasher with a Grote 44892, no more fast flasher. I wish I could remember where I seen this so I could give them credit. I seen people talking about wiring in resistors, but this was just simply changing the flasher relay.

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I had this week off, started by cleaning the shop up, then my son and I tore the transfer case out, I broke one of my 3 jaw pullers trying to get this flange off

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We got it all apart, I came to the conclusion? question? thought? that I don't know how these you tubers always seem to have clean work spaces lol, they must be doing a lot of cleaning in between.

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new KOYO bearings installed, 6.4 gear set installed, case is clearanced for the gears, but when I measured my clearance from the shafts to the case I needed some shims so I have to wait for those to come in.

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waiting on the shims, we tore the front end down, new side gears, and spartan locker. it seems nothing can go easy on this, the shims supplied with the locker were way to thick, I ended up using some thick fender washers that I milled the diameter down to fit inside the locker. I don't know if its because of the brand new gears or what. everything fits snug now though. We got the third put back in but then I got a cold and it sucks, so I have not worked on it in 2 days.

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question for anyone who has rebuilt a samurai transfer case, how many shims are too many between the case and shaft?
 
warrpath4x4 said:
I had this week off, started by cleaning the shop up, then my son and I tore the transfer case out, I broke one of my 3 jaw pullers trying to get this flange off

kKB6wqn.jpg


We got it all apart, I came to the conclusion? question? thought? that I don't know how these you tubers always seem to have clean work spaces lol, they must be doing a lot of cleaning in between.

NTUVoLS.jpg


new KOYO bearings installed, 6.4 gear set installed, case is clearanced for the gears, but when I measured my clearance from the shafts to the case I needed some shims so I have to wait for those to come in.

hGATbfs.jpg


waiting on the shims, we tore the front end down, new side gears, and spartan locker. it seems nothing can go easy on this, the shims supplied with the locker were way to thick, I ended up using some thick fender washers that I milled the diameter down to fit inside the locker. I don't know if its because of the brand new gears or what. everything fits snug now though. We got the third put back in but then I got a cold and it sucks, so I have not worked on it in 2 days.

keND0KW.jpg


question for anyone who has rebuilt a samurai transfer case, how many shims are too many between the case and shaft?
Click to expand...
Youtube videos are edited so I am sure they do lots of cleaning in between.

And for shims, are you sure that a fender washer is a hard enough material?
Shims are usually a very hard material to resist wear.
 
not your typical store bought nerf bar

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this thing is 1/8" thick and welded to the frame, but it hangs down too low for me.
 
with the holidays and cold temps, nothing has gotten done really. I did bring the knuckles and spindles into work and run them through our chemical parts washer and steam washer.

right now were dealing with highs in the teens and low 20's and the shop feels colder inside than outside, makes it very hard to want to do anything so im picking one of these up.


says it heats 1,000 sqft of space, should make it nice and toasty in my 200+/- sqft space lol.
 
I guess we can say i took a vacation? hiatus? pause? laziness? from working on this thing and pretty much all things mechanical. I was also mad at myself for half assing the locker setup when i knew i shouldn't and couldn't bring myself to move on till i fixed it. I was off CK5 for a while but now i am back baby!!

My son ended up joining Boy Scouts and i ended up becoming the Assistant Scoutmaster and that takes quite a bit of time, but a few months ago i started working on this a few minutes here and there, nothing really picture worthy until i got back to work on the axle.

The OEM spider gears in the front need to be removed and you have to use rear spider gears for the longfield axle shafts. I didnt have old spider gears so i bought a set of new ones well the shim that your supposed to remove from the old gear was built into the new ones and made it so my locker wouldnt fit right. I ended up finding a used set of spider gears for free, tore the carrier back apart and fixed my issue. I had been ordering more parts in anticipation so i had a new set of 5.38 gears to install now also.

i love this tool for removing carrier bearings
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my kid being a goof ball and almost getting anti seize in his hair lol
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The best way to hold the carrier while torqueing ring gear bolts
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Then came the new problem, the housing was smashed when i got the samurai and the size difference of the new ring gear, the third member wouldnt fit back in
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I knew this was probably gonna happen and it did
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a week or two went by and i found a set of samurai axles for sale for $500 with 5.38 gears, lockers, crossover steering, and armor. The kid and i loaded up and drove 4 hours to go pick them up. some co-pilot
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Axles came with spacers on them (not sure i will use or not), extra new Aisin hubs and old and new driveline spacers still in the packaging. I have a different steering setup and didnt want to run heims, so i pulled it off and sold it for $100
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while the armor on the front axle looks fine, the rear is kinda janky
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you cant really tell from the picture but the "weld" is almost a copper color almost like it is braised on.
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Thats is pretty much as far as i got because i was "informed" that i had to help deep clean the house before thanksgiving, but afterwards i am going to go back to work and try to have this done for snow wheeling. Also i need it out of the small shop space i have so i can work on the stepside that i have been gathering parts for.
 
got the "new" front axle in the shop and torn down, verifying the third member looks good, the hub bearings needed replaced as they were dragging when spinning them and looks like the short side axle seal was seeping. I have an axle rebuild kit but i need new axle tube seals since i already installed them in the broken housing, I will pick those up tomorrow in town. I had to heat the silicone and ripped the rubber off my dead blow trying to separate the third from the housing, i was about to just bolt it into the Samurai so i could use the jack trick lol.

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Not sure how I did not see this when I pulled the third member out except I obviously didn't look in the housing

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That washer was in there and a ton of metal. The gears look fine and it has a ratcheting locker that seems to be working fine. The previous owner said it had a spartan but I was doing some checking and my longfield axles will not go into the locker gears, so whatever locker it is only accepts stock shafts and i wont be able to use it.

cleaning the grease out to put new axle seals in and this side definitely had a birfield blow up

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put a few hours in here and there the last 2 weeks,

got the front axle put back together (minus some cone washers and bolts for the hubs I'm waiting for )

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Also got the frame rail cleaned up, removed the shock mount, bump stop, and brake line tab. Got all the undercoating off and sprayed some weld through primer but its too cold in the shop to wait for paint to dry lol.

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the frame is cleaned in preparation for stiffener plates, then i will bend up some shock hoops

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