410 transfer case fitted to samurai

[new2zukes]

hi well i got my act together and thought id have a go at getting my 410 t case into my sammy. so i thought why not tell some other ppl how i did it as ive not seen a thread about this yet. so hear goes. only follow these instructions if you dont want to get a warrant again as redrilling holes might not get you a warrant.

1) jack the truck up and place axle stands under the truck.

2)remove 4wd leaver thingy (didnt no what to call it but its in the pic

3)i sugest you clean underneith your truck before you start work as i didnt and when i was nocking things all the mud fell ontop of me (not the smartest idea as you usualy cant see when it goes in ur eyes)

4)remove rear driveshaft bolts and remove driveshaft, you will need this when you redrill flange holes.you might need to get agressive when you take it off as i had to hit it hard with a hammer and a screwdriver to break it free.

5)then remove front driveshaft and gearbox driveshaft its the same as taking the rear driveshaft off.
6) remove 4wd light and speedo cable and just let them droop somewhere out of the way.
7)remove mounting brackets make sure you leave the long edge of the mounting bracket attached to the t case its the one on the right hand side when facing frontwards.
use your trolly jack to lower the t case to the ground as it is reasonably heavy.

9)weld little bits of steel in the mounting bracket as it will bend after some time and will make it very hard if imposible to get in and out of 4wd.

10)take drum off your 410 t case and redrill wholes for samurai flages use clamps to hold in place then weld other holes up.



11)i bought a 410 gearbox to t case diveshaft so i didnt have to alter as many flanges, but the front drive shaft i had to redrill the holes,BUT you run out of meat on the flange so i welded a bit of 6mm pl8 on the other side of the hole. might make it a little out of ballance but i think it will be ok and someone please correct me if its rong:).


i think that is about all you need to do i will be installing it tomorrow and filling it up with some fresh oil.
installing it is the same as the reverse if you havent already guessed.
hope this helps someone and if anyone would like to correct me somewhere then please do as i dont have much machanical experience.cheers


martin

[UBZ]

Instead of Drilling out the transfer flanges to fit the Samurai drive shaft flanges, you could have just changed Samurai ones for 410 flanges (Square shaped).
Then it would have been a straight bolt on procedure.

[icekayak]

I thought this case was gonna be used with hilux diffs you got?

Instead of Drilling out the transfer flanges to fit the Samurai drive shaft flanges, you could have just changed Samurai ones for 410 flanges (Square shaped).
Then it would have been a straight bolt on procedure.

Do you mean put the samurai transfer case flanges from the stock case onto the new 410 t-case?

[UBZ]

Instead of Drilling out the transfer flanges to fit the Samurai drive shaft flanges, you could have just changed Samurai ones for 410 flanges (Square shaped).
Then it would have been a straight bolt on procedure.

Do you mean put the samurai transfer case flanges from the stock case onto the new 410 t-case?

No I mean put 410 Drive shaft flanges onto the stock Samurai Drive shafts /jack shaft at the transfer case end.
As far as I know the Samurai Transfer case flanges wont fit onto the 410 case.

[icekayak]

At the UJ? or the slipjoint?

[UBZ]

At the UJ

[mroffroader]

At the UJ

410 and 413 uj's are not the same???

[UBZ]

The ones I have use the same size UJ. Its a direct swap
84 410 / 85 413. The flange is different. 410 is a square flange / 413 has a Curved side on the flange. As far as I'm aware this type flange was used on the samurai as well.

[icekayak]

Haha i dunno that's suzuki for ya...
That 410 transfer case was the one I had fitted into your LWB UBZ , It bolted straight onto the 413 driveshaft, but the wide track samurai had bigger flanges which would not bolt up to it.
ie in my experience:
'84 410 and 413 are same size flanges
91 WT Samurai and 413 are different size flanges (I don't know about the UJ's).... (and also used different size bolts)
Possible the narrow track samurai/sj413's are the same size?

Someone once told me the flanges from a coily samurai t-case fitted onto a 410 rockhopper case... So may have been possible to swap the samurai t-case flanges onto the 410 case, but i think that is a bit more work and renders the Samurai case un-useable to sell or as a spare without swapping them all back...

These spacers fit 413 and samurai (hence the 2 patterns drilled into them)


But oh well as long as the metal you welded on is even on all sides and the holes are centered it shouldn't be a problem (except at high speed) if its not all centered you'll wear out the t-case mounting bushes and will have some vibration...

[new2zukes]

I thought this case was gonna be used with hilux diffs you got?

my project with the hilux diffs has been put on hold untill i have a shed that i can keep my truck in without parking it up outside as the shed i work in atm is used for joinery aswell as doing stuff to my truck. so i thought why not just use it on my sammy that i use for offroading atm. and im not quite sure if the metal i welded on is even each side but il just have to wait and see how it performs.