Sloppy Shifter (Part 1)
Weak link: Transmission shifter locating bolt.
Models affected: All.
What happens: The factory transmission is notorious for its sloppy shifting. The problem is often related to the shifter locating bolt, which often breaks off and results in this vague shifting.
Strong fix: Replacing this bolt will result in more precise shifting. Just make sure that you get both halves of the broken bolt out of the transmission before buttoning everything back up. The size of the bolt varies by model year, but Petroworks can get exactly what you need at a reasonable price along with a polyurethane shifter bushing for an even more precise feel.
Contact: Petroworks.
Sloppy Shifter (Part 2)
Weak link: Transfer-case shifter sheet.
Models affected: All.
What happens: The transfer-case "shift sheet" is a donut-shaped bushing that is located under the shift lever. Virtually all Samurais have or will be affected by this part failing at some point in time. When the seat fails, the transfer case will be stuck in Neutral or locked so that it will not turn. Many a savvy Suzuki owner has purchased a Samurai for pennies on the dollar when the seller thought that the transfer case was broken, when in fact the real culprit was the shift sheet.
Strong fix: The fix for the shift sheet is very simple and can be performed from inside the truck with just a screwdriver. While an OEM replacement part is available, a better option is to use a more durable polyurethane shift sheet such as the one available from Petroworks. You can even get a kit with the transfer-case bushing, transmission bushing, and transmission shifter bolt all together.
Contact: Petroworks.
Axle Armor
Weak link: Stamped differential housings.
Models affected: All.
What happens: The differential housings on Samurai axles are made out of thin sheetmetal. This may be cost-effective for the manufacturer, but if a rock bends the cover into the ring gear, you can expect to pay big bucks on the repair.
Sturdy fix: Petroworks offers 0.375-inch steel "pumpkin caps" that are easily welded to the differential covers for added protection.
Contact: Petroworks.
Thief Repellent
Weak link: Lack of storage.
Models affected: All soft-top models.
What happens: As with many other open-top rigs, lockable storage is at a premium in the Samurai. Leaving your vehicle unattended with the top down is an invitation for less desirable types to help themselves to your belongings.
Strong fix: Tuffy Security Products manufactures lockable center consoles out of heavy-gauge steel and outfits them with its Pry-Guard locks. Now you have a place to stash your stereo, sunglasses, or GPS without worrying about it disappearing.
Contact: Tuffy.
As The Birf Turns
Weak link: Birfield joints.
Models affected: All.
What happens: Unlike Dana axles, Samurai axles use Birfield joints instead of U-joints to facilitate steering on the front axle. When placed between low gears and tall tires, the Birfields often become the weak link.
Strong fix 1: Spidertrax has come up with a simple solution to strengthen the Birfields. A ring is installed around the Birfield that keeps it from expanding, and thus breaking.
Strong fix 2: If Birfield rings are not enough to end your breakage problems, the next option is to upgrade to CV Unlimited's Samurai Newfields. These joints replace the stock Birfields and feature greater resistance to breaking, thanks to the improved materials, heat treating, and cryogenics.
Strong fix 3: Want to get rid of those messy Birfields altogether, gaining strength and improving turning radius in the process? The Spidertrax Sidewinder open-knuckle front axle replaces the stock Birfields with U-joints and 26-spline chromoly stub shafts. The housings accept Sidetrack third members and use stock Samurai hubs, spindles, and brakes.
Contact: CV Unlimited, Spidertrax.
Oil Spots
Weak link: Leaky engine.
Models affected: All.
What happens: Most Samurais seem to leak oil from the back of the motor. With only 3.7 quarts of oil in the case, you cannot afford to lose any!
Sturdy fix: Fortunately, the fix is often easier than changing the rear main seal. The O-ring on the distributor is usually the culprit. Petroworks offers new O-rings that will seal up the distributor tight.
Contact: Petroworks.
Up The Amps
Weak link: Alternator.
Models affected: All.
What happens: The stock Samurai alternator delivers 40 amps of current. That may be enough to run the headlights, but if you have added a winch or auxiliary lights to your rig, the charging system is probably having a hard time keeping up.
Strong fix: Petroworks offers kits to retrofit a Delco alternator from a GM vehicle with up to 105 amps. The kit comes complete with the alternator, brackets, wiring, and bolts. Now you can winch your Suzuki at night with all of the lights on without worry.
Contact: Petroworks.