Join Date: Aug 2000
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Re: SJ410 Axles
Make sure you get 1986 or newer samurai axles, the 1985 are the same width as your axles altho the axle shafts are bigger and all the parts cept the axle shafts will work in a newer diff.
When you have the newer axles, you need to weld on the spring perches, they will be inboard more, not directly ontop of the old perches, because if you look on your truck, the shackle mounts are inline with the frme and if you look at a newer samurai they are on the outside of the frame,.. 1.5" on the front i belive, not sure if the rear is the same or not.
For the brakes, since your zuk is an 82, it has drum brakes all around. The newer front axle will have disc brakes, so yu will need the different kind of brake lines, the front brake lines from a suzuki swift work perfect for SPOA. Now for the rear, if you look there is only 1 rubber brake line, and the newer diffs have 2, except for the 89 and up i belive. When i put some newer diffs on somones 84 SJ 410, i used a little "T splitter" thing, which will turn the 1 line into 2..this works fine but your brakes may feel spongy because the newer brakes are different and the samurais have a bigger master cylinder than the SJ 410's. you will need the spring plates and ubolts from the newer truck too. now steering, the drag link on the older ones are shorter than the newer ones, if your going to cut it up and make a Z bar thats not a problem because you can just lengthen it to 30" or whatever it is.
For the driveshafts, you need to put the newer flanges on the end, on the u-joints, because the samurais have a bigger bolt pattern. This is easy because the samurai and sj 410 u joints are the same cept the sj 410s have internal snap rings on the u-joints.. Just use the external ones when you put the newer flanges on.
Remember that if you dont get gears for your new axles you might have a little problem because the stock SJ 410 gears are 4.10:1 and the 86+ samurais are 3.73:1
I think i covored evrything there, good luck..If you run into trouble i know rgd did this swap, you can always ask him for some more help.
87 Suzuki Samurai JX, Hybrid SPOA, expander shackles, removable doors, coustom bumpers, gator guard 2 interior, fast back top, rear locker, 31's, GM100A Alt, 2, 33's. 740 RTI