Suzuki Samurai Axle Upgrade - Toying With Sami

Randy's Ring & Pinion supplied two Yukon Gear & Axle 5.29 gearsets for the front and rear axles, as well as install kits complete with bearings and seals.

For guaranteed positive traction through difficult obstacles, we'll install Detroit Lockers in the front and rear.

A set of Warn premium hubs will replace the stock Toyota hubs. For Toyota pickup applications, the Warn hubs also require use of a spindle nut conversion kit.

In order to the mate the front Toyota axle to the stock Samurai steering system, we used Trail Tough's Toyota-to-Samurai Hysteer kit. The kit includes new steering arms, the correct-length tie rod and drag link, and Toyota FJ80 rod ends.

We began assembly of the front axle dropout with the installation of the Yukon pinion gear and bearings.

The Yukon ring gear was bolted to the Detroit locker using the provided bolts.

The Detroit Locker and ring gear were then installed in the Toyota dropout.

Proper backlash was set using a dial indicator. We also observed the ring-and-pinion teeth contact pattern to ensure that it was correct.

With assembly of the axle dropouts complete, both were installed in their respective housings. We then went on to install the Trail Tough steering arms on the front axle and test-fit the tie rod and drag link.

The Jeep Wrangler YJ leaf-spring packs were situated atop the spring perches. In order to accommodate the longer springs, the front of the frame was extended 6 inches and a new crossmember with built-in spring hangers was fabricated.

The leaf springs were bolted to the new, wider perches on the axletubes and secured in place. Note the ample clearance between the springs and the Trail Tough tie rod, as well as the beefy gussets across the front of the axlehousing.

Here the front end is shown nearly complete. We were impressed with how easily the Trail Tough Toyota-to-Samurai Hysteer kit was installed, as well as with how well it performs.

The Warn premium hubs were installed along with the spindle nut conversion kit. The Pro Comp/Rockstomper beadlock wheels were also installed. The massive Rockstomper mud rings appear to nearly engulf the hub.

The rear axle was placed under the vehicle, and the spring U-bolts were installed to determine proper location. Once we were happy with the positioning, we tacked the spring perches in place on the axletubes.

Prior to bolting up the rear axle assembly in the vehicle, we finished installing the All-Pro Off-Road rear axleshafts and rear disc brake conversion.

The wheelbase of the Samurai was stretched 15 inches in the rear. Modified spring shackles and hangers were used to support the rear leaf springs.

Though it could use a few coats of paint, our RocZuk Samurai is almost ready for the trail. We'll still require new driveshafts before it's completely operational, but otherwise the rig is well on its way to becoming an off-road hero.