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Samurai Transfer Case
Everything you need from behind your transmission down to the
pinion flange to get your rig geared and crawling slow. |
Gear Set Comparison Chart |
Gear Set |
4.16:1 Gears |
4.9:1 Gears |
6.4:1 Gears |
6.5:1 Gears |
Low Range Reduction |
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High Range Reduction |
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Suggested Tire Size |
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Gear Kit Price |
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Rebuilt Case Price |
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6.5:1 Low Range Transfer Case Gears
Low range gears are critical for technical off-road driving. Our Samurai low range gear kit is the highest quality gear set available. Low Range reduction is 6.5 to 1, a whopping 187% lower than stock! High Range reduction is 20%, perfect for the larger 32" and bigger tires. These gears are NOT WELDED or second rate. These are are strong, run quiet and take a huge amount of abuse. This complete kit includes four new precision cut gears, counter shaft, needle bearings, shims, o-ring, gaskets, and input/output seals. Updated front output shaft recommended for tires 31" and bigger (see below). Minor grinding of case is necessary for installation, see instructions link bellow for more details. Lifetime Warranty on gears. Fits 1986-1995 Suzuki Samurai's. Made by Trail-Gear. No cores are required.
Install Instructions
6.5:1 Low Range Fully Rebuilt Transfer Cases
For those who do not want to attempt putting together their own case, we are now doing this for you. We can take your case and fully rebuild it with the 6:5.1 gears installed and ready to run. We first fully dismantle the case. Clean it in solvent and then bead blast the case so you get one back that looks brand new. If any mounting holes are damaged we take care to drill and tap or helicoil them if needed so you have a hassle free install. We also paint your flanges black to avoid rust and corrosion. The bearings are carefully replaced. You can also choose to have us install the HD Transfer Case Front Output Shaft below. Comes ready to install, fill with oil and go. You can either send in your core first to avoid the core charge or after and we can refund you for no down time. Lifetime warranty on gears only through our supplier and a limited 1 year warranty against manufacturer defects on case itself through us, call for details. Case breakages are NOT covered. Shipping generally runs from $35-$55 per case.
6.5:1 Transfer Case
Price: $799.00 |
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6.5:1 Transfer Case w/ Updated Output
Price: $888.00 |
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$250 core charge.
*ASK US ABOUT DIFFERENT SHIFT PATTERNS AVAILABLE! |
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6.4:1 Low Range Transfer Case Gears
If your running around a 32 or bigger tire on your Samurai and want to get that 5th gear back, these are your ticket. This kit provides a high range reduction of 17% and an awesome low range reduction of 181%. These one-piece billet gear sets run quite and provide superior reliability. Updated front output shaft recommended for tires 31" and bigger (see below). Minor grinding of case is necessary for installation. These kits include new gaskets, seals, thrust washers, counter shaft, 2 needle bearings, O-ring, and even a new shift sheet. These are fully billet, non welded gears so no cores are required.
6.4:1 Low Range Fully Rebuilt Transfer Cases
For those who do not want to attempt putting together their own case, we are now doing this for you. We can take your case and fully rebuild it with the 6.4:1 gears installed and ready to run. We first fully dismantle the case. Clean it in solvent and then bead blast the case so you get one back that looks brand new. If any mounting holes are damaged we take care to drill and tap or helicoil them if needed so you have a hassle free install. We also paint your flanges black to avoid rust and corrosion. The bearings are carefully replaced. You can also choose to have us install the HD Transfer Case Front Output Shaft below. Comes ready to install, fill with oil and go. You can either send in your core first to avoid the core charge or after and we can refund you for no down time. Lifetime warranty on gears and a limited 1 year warranty on case, call for details. Shipping generally runs from $35-$55 per case.
6.4:1 Transfer Case
Price: $969.00 |
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6.4:1 Transfer Case w/ Updated Output
Price: $1058.00 |
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$250 core charge.
*ASK US ABOUT DIFFERENT SHIFT PATTERNS AVAILABLE! |
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4.9:1 Low Range Transfer Case Gears
If your running around a 31" tire on your Samurai and want to get that 5th gear back, these are your ticket. Trail Tough's "Rock Monster" series 4.9:1 transfer case gears provide 115% reduction in low range and 16% reduction in high range.
These one-piece billet gear sets run quiet and provide superior reliability. These are the most complete kits currently available and include new gaskets, seals, thrust washers, counter shaft, 2 needle bearings, an O-ring, and even a new oem shift sheet. No cores are required.
4.9:1 Low Range Fully Rebuilt Transfer Cases
For those who do not want to attempt putting together their own case, we are now doing this for you. We can take your case and fully rebuild it with the 4.9.1 gears installed and ready to run. We first fully dismantle the case. Clean it in solvent and then bead blast the case so you get one back that looks brand new. If any mounting holes are damaged we take care to drill and tap or helicoil them if needed so you have a hassle free install. We also paint your flanges black to avoid rust and corrosion. The bearings are carefully replaced. You can also choose to have us install the HD Transfer Case Front Output Shaft below. Comes ready to install, fill with oil and go. You can either send in your core first to avoid the core charge or after and we can refund you for no down time. Limited 1 year warranty on gears and case, call for details. Shipping generally runs from $35-$55 per case.
4.9:1 Transfer Case
Price: $835.00 |
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4.9:1 Transfer Case w/ Updated Output
Price: $924.00 |
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$250 core charge.
*ASK US ABOUT DIFFERENT SHIFT PATTERNS AVAILABLE!* |
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4.16:1 Low Range Transfer Case Gears
If your running up to a 30" tire on your Samurai and want to get that 5th gear back, these are your ticket. Trail Tough's economical 4.16:1 gear set. 84% low range reduction and 12% high range reduction.
These are fully billet, non welded gears so no cores are required. Basic kit comes with parts shown and is all that you need to get up and running. Crawler kit comes with seals, gaskets and new shifter sheet.
Basic Kit
Price: $399.00 |
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Crawler Kit
Price: $423.95
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4.16:1 Low Range Fully Rebuilt Transfer Cases
For those who do not want to attempt putting together their own case, we are now doing this for you. We can take your case and fully rebuild it with the 4.16.1 gears installed and ready to run. We first fully dismantle the case. Clean it in solvent and then bead blast the case so you get one back that looks brand new. If any mounting holes are damaged we take care to drill and tap or helicoil them if needed so you have a hassle free install. We also paint your flanges black to avoid rust and corrosion. The bearings are carefully replaced. You can also choose to have us install the HD Transfer Case Front Output Shaft below. Comes ready to install, fill with oil and go. You can either send in your core first to avoid the core charge or after and we can refund you for no down time. Limited 1 year warranty on gears and case, call for details. Shipping generally runs from $35-$55 per case.
4.16:1 Transfer Case
Price: $649.00 |
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4.16:1 Transfer Case w/ Updated Output
Price: $738.00 |
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$250 core charge.
*ASK US ABOUT DIFFERENT SHIFT PATTERNS AVAILABLE!* |
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Rear Driveline Disconnect
This compact unit simply replaces the rear drive shaft flange of the Samurai transfer case. It is a great alternative for the Samurai owner who can take advantage of the benefits of all of the various new transfer case gearing options and have the ability to "burn-turn" or do front wheel digs......just like the guys with the Atlas cases! This rear drive disconnect made by Trail Tough works not only for the serious wheeler's burn-turning needs, but also works excellent for disconnecting the drive shaft for guys who just want to flat tow. Comes with all needed hardware and shifter handle.
Cutting a hole in your tunnel for shifter is necessary.
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Twin Stick Shifter
Interior Boots
Your choice of two great interior boots for your twin stick
kits. One is hand made with high grade vinyl fabric specifically
for the Samurai and the other is a great looking rubber
one that is originally made for Dana 300 Tranfercase
twin stick but is easily modified to work in the Samurai.
Both come with a great price.
Fabric "Evil Twin" Style
Price: $20.00 |
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Rubber D300 Style
Price: $20.00 |
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Here is some info for those wondering what a twin stick
does and why you need one. A twin stick shifter is
by far the best way to allow your case to have low range
gearing in both four wheel and two wheel drive. A whole new
option to make the trail that much more fun. Another great
thing that the twin stick adds is a "true neutral"
for those towing their Samurai. The stock Samurai case
does not have a true neutral. This means that if you tow your
rig, all the gears in the case, front driveline, front axle
and transmission are all turning adding unneeded wear to your
components.
A good Twin Stick Kit is a far better route than the
"Sloppy-H", "Reverse-S" and other pattern
changes in the market.
Please call or e-mail us if you have any questions on
Twin Stick kits.
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Updated 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 1994 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 1986-1993 transfer cases. You can see the difference in the picture, the older version is on top and the upgrade on the bottom. This upgrade is especially good for transfer cases that have lower than stock gearing in them because the lower the gear, the higher the torque load going through the gear.
The front output gear can be installed without full dis-assembly 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.
Shaft
Price: $89.00 |
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Shaft w/ Pilot Bearing
Price: $96.00 |
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Transfer Case Rebuild Kits and Parts
If you are installing new gears or if your case just needs some TLC, we have you taken care of. Choose from Complete Kits, Lower Gear Install Supplement Kits, or Standard kits (Pictured). You can also get just a gasket and seal kit. Ask us for individual parts prices as well.
Complete Rebuild kit
(5 Roller Bearings, 2 Main Needle Bearings, Front Output needle Bearing, Counter shaft, 2 Counter Needle Bearings, 2 Thrust Washers, 1 O-ring, 2 Gaskets, 3 Seals)
Price: $215.00 |
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Gear Install Supplement Kit
(5 Roller Bearings, 2 Main Needle Bearings, Front Output needle Bearing)
Price: $115.00 |
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Standard Rebuild Kit (pictured)
(5 Roller Bearings, 2 Gaskets, 3 Seals)
Price: $79.00 |
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Rear Output/Main Shaft
Price: $129.00 |
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Transfer Case Hardware
Miscellaneous tcase hardware you might need to finish your build.
Flange Nuts
Price: $8.00 each
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Shifter Boot and Clamp
Price: $17.00
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Replacement Breather
Price: $4.00 each |
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Speedo Retainer Bolt
Price $2.00 each
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Speedo Gear
Price: $24.00 each |
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Speedo Gear Housing
Price: $8.00 each |
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Speedo Gear O-ring (2 needed)
Price: $2.00 each
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Speedo Gear Oil Seal
Price: $2.00 each |
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Lower Wire Tie Clamps (2 needed)
Price: $4.00 |
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4wd Light Switch
Price: $21.00 |
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4wd Switch Detent Ball
Price: $3.00 |
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Sloppy Shifter Fix Bushings and Bolts
Is your transfer case stuck in neutral? Is your Transmission shifter sloppy? These are some of the most common problems with the Suzuki Samurai. Replace those stock shifter bushings and shifter bolt with the new and improved polyurethane or brass replacements and new OEM bolts.
They are easy to replace and can be done without pulling you transmission or transfercase out of the vehicle.
We do not have a preference between the Brass or Polyurethane. Both hold up very well and are great products.
Full Shifter Kit
Comes with your choice of Poly or Brass Transfer Case Sheet and Transmission Bushing and 1 bolt.
Price: $33.00 |
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Brass or Polyurethane (Orange) Transfer Case Shifter Sheet (View install)
Price:$14.00
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Transmission Shifter Bushing
Price: $18.00 |
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Transmission Shifter Bolt
Price: $2.00 |
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"Mighty Kong" Transfer Case Mount
The popular "Mighty Kong." made by Trail Tough This is combonation transfer case mount, bucket and skid plate made for the Suzuki Samurai. With its one peice design it will not flex or distort and actually adds strength to your case. It provides protection where you need it - not where you don't and weighs only 12 lbs. It is also designed to accommodate drum or disc e-brake upgrades. Mounts to the stock mounting points on your case.
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Spidertrax HD Transfer Case
Mount
When off roading your Samurai its not a question of if, but
when. Even with stock gears we have seen the factory transfer
case mounts fail and most of you will be adding aftermarket
lower gears that put more stress on these mounts.
The Heavy Duty T-Case Arms works with our aftermarket Polymount
Kit and the original OEM rubber mounts. It also works with
the E-Brake Kit and any other t-case mounted e-brake.
This product comes with both arms and all hardware needed
for the install. The arms are powder coated silver for superior
corrosion resistance. The HD T-Case Arms are guaranteed to
be the best t-case mounting system on the market.
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Billet Aluminum
Shifter Knobs
These CNC machined billet aluminum shifter knobs feature either the Stock Transmission Shift pattern, stock transfer case shift pattern, split "H" shift pattern, the Suzuki "S" Logo or the Spidertrax Spider Logo and fits both the Samurai transmission and transfer case shifters.
Make your choice from:
• The Spider (View)
• Suzuki "S" Logo (View)
• Transmission Shift Pattern (View)
• Stock Transfer-case Pattern (View)
• Split "H" Transfer-case Pattern(View)
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