Join Date: Jan 2003
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Re: Samurai Steering Gear Box questions,
My 88 was making a groaning noise and after removing the filler plug I was unable to even see any oil, so I added some gear oil and got it too full and it started to leak out of the vented plastic filler plug since this plug has a big dang hole thru it. But it stopped making the noise! You can add oil by just removing the metal cap on the plug instead of unscrewing the entire plug.The rest of this post is text I've pasted from a post of mine about this subject.
The stock plug is plastic & has a lame tin metal cap on top. It seems to me that dirt & water could enter at will. So I snagged a metal plug off an 1990 Samurai and it's the ticket. This one has a nipple on top with a spring loaded rubber seal built into the cap piece. Suzuki finially got wise and solved the problem. Also this newer plug is hex shaped so you can use a 17mm wrench or socket to remove or install it. Considering all the posts I've seen about sloppy steering I think everyone needs to go and check their manual steering boxes right now! Hurray up and go do it right now. As my wife would say " I told ya that 40-11 times "
Hope this helps, cuz it's the little things in life that bring us pleasure.