Suzuki Samurai Driveline Buildup - Project RocZuk Wrapup

The CV (double-Cardan) driveshaft is equipped with Tom Wood's Super-Flex driveshaft U-joints.

In order to install the CV shaft at the rear, Tom Wood's provided a custom adapter flange that bolts to the rear output of the Suzuki transfer case and accepts a CV driveshaft. The adapter is machined from T6 aircraft-grade aluminum billet.

The crew at Tom Wood's used a lathe to machine out 1 mm of material from the '88.5-and-later Suzuki front output flange.

The front driveshaft installed.

Calmini's ultralow 6.5:1 DL Rockcrawler gearset is installed in the RocZuk's T-case. A heavy-duty transfer-case mount cradle, also from Calmini, was installed to resist the rotational force of increased torque of lower transfer-case gears.

We continued the do-it-yourself nature of the RocZuk by equipping a set of 15x8 Pro Comp Rock Crawler steel wheels with Rockstomper DIY beadlocks. Once installed, the beadlocked wheels were wrapped with 35x12.50R15 Pro Comp Xterrains.

The rear Toyota axle uses All-Pro chrome-moly axleshafts and a disc-brake conversion kit.

A custom front stinger-style bumper and winch plate were constructed to house a T-Max EW-9000 winch. A power steering system was installed using a Suzuki Sidekick power steering pump and steering box. A Trail Tough Toyota-to-Samurai Hysteer system was used to mate the Toyota steering knuckle to the Suzuki pitman arm. The kit included new steering arms, the correct-length tie rod and drag link equipped with larger Toyota FJ80 rod ends.