Symptoms
A clunk when you shift on and off the throttle, a transfer case that sags or rocks, a cracked mounting boss or a frame bracket starting to tear. Lower transfer-case gears make it worse.
The fix, step by step
- Support the transfer case, unbolt the mounts and inspect the frame hangers.
- Trail Tough's repair kit restores the wallowed-out hole and bent rear hanger, and you can fit it before or after the frame is damaged.
- Replace the rubber mounts with OEM or solid ones, or fit a cradle that supports the case on three axes.
- Trail Tough also points out that gearing down only at the transfer case overloads these mounts, so regear the axles too.
Tools & part numbers
- Jack and stands
- welder and grinder
- drill
- socket set
Where to buy the parts
Transfer case / frame mount repair kitTrail Tough ↗Amazon ↗
OEM Suzuki rubber transfer case mountTrail Tough ↗Amazon ↗
Solid transfer case mounts (set of 3)Trail Tough ↗Amazon ↗
Mighty Kong II transfer case mount / skid plateTrail Tough ↗Amazon ↗
Hunting a used or discontinued part? Search eBay Motors for Suzuki SJ / Samurai parts →
Rated for a competent home mechanic with a decent tool kit. Confirm torque figures, fluids and procedures against the factory service manual for your VIN, support the truck on stands rather than a jack, and work at your own risk (disclaimer). Some parts links are affiliate links, which pay us a small commission at no cost to you.