any sj410 t-case will give you some lower gearing,12 percent high and low range, if you get lucky enough to find an 84 you can send the middle gear(the one piece with two gears on it) out of the sami and the sj to a company called Breeze industries, they hack it in half and put the lower sj gear onto the sami, gives you the same gearing as the gr1 kit, cost= the price of the t-case + $200 Canadian. You could probably get a good machine shop to do the same for you, Breeze is the place that did mine, 12 percent lower in high range and 86 in the low range.

 

Does the 12 percent in high range mean 12 percent faster speed in 4th and 5th gear? -Drew

86 Sami, extended shackles, running 31's, SPOA in the near future

 

12% lower geared than stock.

-Farther

 

sj410x,
i was thinking of spending the big bucks for the gr1 kit but it so happens that i know where theres a 410 t-case i can get for nothing. can u explain this indepth a little more such as the gear to shave and the thickness it needs to be shaved to. i have access to a milling machine and it should not be a problem if i can get the specs,,,,,
thank u,

89 XJ, 9+" LIFT, LOCKED, 4.56, 4.1 LR, 38 TSLs, MANY OTHER MODS..
90 zuki, 5.5 spoa, 5.12 gears, 31 boggers,, lockers and 4.16 t-case gears next.

I LIKE IT DIRTY,
XJ89XJ

 

XJ89XJ,
If you don't do the convertion, I may want to get that tcase off of you. Private me in the future with price if this may happen. -Drew

86 Sami, extended shackles, running 31's, SPOA in the near future

 

Alright since I don't know i've got to ask this: Does lower gearing mean a faster speed? I would like to hit 80 mph, thats the max. Will this be better than stock to go 80 mph on the highway? When I do go zukin I'm gonna have to drive the sami to that place, not have it on a trailer. I also don't want to be at 5 grand rpm at 80 mph. What would be best for me? Thanks, -Drew

86 Sami, extended shackles, running 31's, SPOA in the near future

 

What tire size, it plays a big part. With stock tires, you will be slower, and at higher RPM's.

ICQ# = 3859170
There's a new Sami website in town, and its...
http://members.home.net/micahis

 

The 31's I have now and maybe 33's, make suggestions to both sizes. Thanks, Drew

86 Sami, extended shackles, running 31's, SPOA in the near future

 

Go for the 4.16 kit or modify the 410/Samurai gears for the 4.16 range. Unless you do straight mud bogging or don't have the funds to convert the case, don't even both with the baby lobster (SJ410 case without 4.16 mod). Unless you really know what your doing, I recommend sending the gears to someone (RRO, Petroworks, etc.) that has cut/welded the cluster gear before.

The 4.16 low range will help give you control in nearly ever offroad situation. IMHO, it is the minimum needed with 31" tires-even with a 1600 engine. You really don't even need touch the ring/pinion with this tcase. I also recommend going with the 88.5 later (.865) fifth gear if you don't already have it.

I'd stay away from 33" tires unless you plan to swap axles. Otherwise, you'll be twisting splines/breaking birfields every time you go out.

Jonathan Hall
Captain, US Army
Camp Doha, Kuwait
http://www.geocities.com/gi_zuk/

 

On the pic attached, you need the gear circled in red from both the sami case and the sj410 case. I think you would be better off to send them to someone who has done this before, they cut the gears in half and weld the small sj gear to the large sami gear. when you get that back, you also need the gear circled in blue from the sj410 case, put all the gears back together in the sami case. The most important part of the whole opperation is that it HAS be an 84 t-case, no other year will work.

 

another thing you can do is take the e-brake assembly off the sj t-case and mount it to your sami case to elliminate the e-brake on the rear axle. nice to have if you swap in axles from something else.

 

I think I'm gonna stick with stock tcase and go with 32" tires. I'm looking for the cheapest way to go with thisand still be able to get 80 mph. Would doin a ring and pinion be my answer? Can the set be bought for a good price, if so where? What gearing should I look for? Drew

86 Sami, extended shackles, running 31's, SPOA in the near future

 

just swaping in an sj case would be the easiest way to get 12 percent lower and would be cheaper than doing the axle gears. running 32's with the stock axle gears and t-case gears will suck off road

 

Your stock t-case will give the the greatest top end speed if you have the horsepower to drive it. The 1.3 needs the lower gears (higher numerically) in order to keep the RPMs in the power band. All four cylinder engines built for autos develop their horsepower at higher RPMs, so they need the lower gears (higher numerically) to efficiently use the engine power. You need lower gears to compensate for larger diameter tires. The larger the tires, the lower the gears. Horsepower comes in here too, needed to drive the greater weight of the tires and geater rotating mass. Clutch and brakes suffer with larger tires too.

You will be lucky to see 80 mph with the 1.3 with stock t-case gears and stock size tires. You probably can see 80 mph in any t-case gears with the 1.6, 16 valve engine with any tire 31" or less.

On the flat with no wind I can sometimes see 75 mph on a good day with my 1.3 and 30" tires in 5th gear. I have a stock t-case and 1.3 with KN filter and DT header and find it bearly adequate for offroad on fire trails and mining trails.

If you are concerned about onroad driving the most and you are going to install a 1.6l 16v, stay with the stock t-case until you determined what your driving needs are. If you have access to the older t-case with the lower gears, get it and keep it for the future.

-Farther

 

I have an SJ410 T-case, 88.5 tranny, a DT header w/ 2 in exhaust and 31s. I can hit 80mph and my engine has a bazillion miles on it. I guess I'm lucky....

Don't even try to run the SJ410 case with smaller tires. It won't work very well. If you stay with smalle rtires stay with the stock T-case and swap engines.
AARRRRRRRG! 1987 Red JX 'vert, 4.5 BREEZE SPOA, SJ410 T-case, 31 BFG M/T knock offs, extended shackles (1.6 - 16V eventually)

 

hmmm - now you guys have me wondering - I have a case in my basement of 'unknown' vintage - defintely from an SJ, w/ 1.6:1 high, and ~2.6:1 low....whats so different about the '84' vs other years, and can I tell from the ouside of the case what year/model it is??

Chris

91 Niva MB 240D, 88:1 low, 30x9's, coil sprung, 830 RTI.

 

It'll look nearly identical to the Sami T-case. The pilot shaft needs to be sticking through the front (just like the Sami's). It'll also have a 4WD plug for the light.

AARRRRRRRG! 1987 Red JX 'vert, 4.5 BREEZE SPOA, SJ410 T-case, 31 BFG M/T knock offs, extended shackles (1.6 - 16V eventually)

 

ah well - just another 410 case. just for my curiosity, what are these things 'worth' - either $$, or in trade for ?. ( shameless plug here - I'm looking for a cheap locker I can hack apart to try fitting it into the Niva's diffs - 6.1" ring gear, so sammys/sj's are about the only donors!)

chris

91 Niva MB 240D, 88:1 low, 30x9's, coil sprung, 830 RTI.

 

Okay as I mentioned before in this post that I have a tracker 2wd and I'm goin to put that engine and tranny in my sami. With that and stock tcase and stock gears will I be able to do some offroading, not nothin big and I still want to hit 80 mph. The tracker itself will hit 95 mph easy. Should I get different axle gears, or a different tcase, or stick with the stock tcase and stock axle gearing? The 1.6L and tracker tranny is goin in reguardless what I do to the axles or tcase. Drew

86 Sami, extended shackles, running 31's, SPOA in the near future

 

Is the 1.6l a 8v or 16v?

-Farther

 

8v and stickin with the efi. Drew

86 Sami, extended shackles, running 31's, SPOA in the near future