Symptoms
Sloppy or stiff transfer case lever, trouble finding 4WD or low, a case that pops out of gear, and leaks at the output seals.
The fix, step by step
- Drain the case.
- Remove the shifter boot and the top cover, replace the worn plastic shift sheet, check the shift-rail springs and detents, then reseal the cover and output seals with the seal kit.
- Refill with gear oil (Trail Tough recommends non-synthetic 80W-90 GL-5 in its rebuilt cases) and check that 2H, 4H and 4L all engage.
Tools & part numbers
- Socket set
- seal puller and driver
- gasket scraper
- fluid pump
Where to buy the parts
OEM shift sheetTrail Tough ↗Amazon ↗
Lifetime Delrin shift sheetTrail Tough ↗Amazon ↗
Samurai transfer case seal kitTrail Tough ↗Amazon ↗
Factory transfer case ventTrail 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.