Samurai Differential Rebuild

Because of the great interest in changing the ring and pinion gears in an effort to improve the offroad gearing on a Samurai, I have created a zip file containing JPEG images of Chapter 16 - Differential from the 1988 Samurai Factory Service Manual.

This chapter describes in detail the process of:

Tearing down the front axle and the rear axle in preparation for removing the third member.

Removing the third member (see also Samurai Front Axle Disassembly and Third Member Removal for a "Shade-Tree Mechanic" method).

Disassembling the Third Member

Setting the backlash

Setting the Pinion-to-Gear contact

Torque specifications

Reassembly and installation

Naturally, information concerning aftermarket parts installation (spider gear retainer cans, spools, lockers, etc.) are not included.

The 16 pages of this chapter were saved in a high-quality JPEG format to ensure crisp, readable text, drawings and pictures. Use your printer's reduction/enlargement tools along with the margin properties firelds to fit the images onto an 8.5 by 11 inch sheet.

You will need a program that "unzips" compressed files. Newer versions of Windows and WinZip (available on the Internet at http://www.Winzip.com) can do this.

Here is the file: