Jordis 1988 Samurai (Re)Build

[Jordi]

Finally started work on it today. Thought id do the springs. Nice and easy only a few 26year rusted bolts.

In a whole day managed to change one spring. Removing the shackles was easy. Removing the spring to chassis mount was a whole new challenge. I thought the biggest problem would be bolts shearing. Never even thought about it being seized to the bush insert.

Method 1. Just unbolt it. Bolt seized solid to metal bush insert.
Method 2. Unbolt it and bray with a 5lb'er. Its really seized.
Method 3. The blow torch. Burn the bush out and heat the bush insert then bray with the hammer.
Method 4. 9" grinder. new bolts. Where to get 100mm high tensile steel bolts on boxing day? Job bodged together for now. Hopefully screw fix is open tomorrow.

It's a good job i've got new springs as the rivets and wraps on the old springs are about done.

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I only went for 1.5" springs hoping that the standard shocks would be ok. But even on full stretch they don't reach from chassis to spring. Longer shocks required.

Any suggestions?

Cheers

Jordi

[Jordi]

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[Jordi]

As you can see in the second set of photos we now have bump stops too. I already have some steel box section to make extentions. Just got to remember to retrieve my welder from my Dads shed!

[ScottieJ]

The old faithful seized spring bush sleeves eh!!! I cut the bolt head off and then prize the hanger out a bit so that you can get a 1mm slitting disc up between the hanger and the bush, works a treat I'm sure the other 3 will go a bit quicker now that you know that though

Oh and don't forget to chop the excess off the bottom of the Ubolts.

[Jordi]

Cheers Scottie.

Yeah, now i know what to do its just gona be a case of cut the bolts out and replace them. The existing bushes are that shot if i pry the spring to one side i can get a thin cutting disc in the gap.

I've tightened them bolts as far as my socket will allow. When i've got both sides done i'm going to chop the excess off the u bolt and torque them up. Fairly sure henrys write up in the diy section had torque settings in it.

Jordi

[dan_2k_uk]

Seem to remember with a 115mm grinder it was a case pf 1mm slitting disc up the side then rotate the bolt/bush then repeat. Seemed to take forever. Replaced with stainless and polybushes!

[Darrell]

Been there, done that

http://www.suzukiclubuk.co.uk/index.php ... =15&t=3717


PDF file of the suspension section from the workshop manual with all the torque settings is here
if you want it http://www.4x4.in.th/manual_sj413/chapter17.pdf

[Jordi]

It's taken an hour and a half of shopping around. Trying every motor factors, bolt suppliers and builders merchant in Darlington. Only to be told "teesside fasteners mate, they're open and they'll stock em"

Quick trip to stockton and we now have four 100mm partially threaded M12 bolts, nuts and spring washers.

Time to crack on!

[Jordi]

Job nearly done. Its all together, 4 new springs fitted. And the front shocks fit fine with plenty of travel left.

After the chew on getting the rear spring hanger bolts out the front ones just pulled out, straight out.

Last jobs on suspension are to cut u bolt excess off, torque it all up and fit new (or modify) rear shocks to fit. Haven't measured the amount of lift yet.

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I'll get some more photos up when its all torqued up and ok to move about easily.

I took a quick glance at the props, front prop looks ok, not sure about the rear one.

Jordi

[Darrell]