Build 1988 Samurai Turned Buggy

It doesn't look like a roll pin problem. The roll pin should be flush with the shift fork or slightly recessed which it looks like yours are.
If this case was run with the stock single J shift stick and you didn't remove the interlock pill between the shift rails to operate the twin sticks, that is your problem.
 
He can get it into 4Hi though. If the interlock was still there he would be able to get from 4Hi to 4Lo still.
 
SKULLYOTA said:
He can get it into 4Hi though. If the interlock was still there he would be able to get from 4Hi to 4Lo still.
Click to expand...

Yeah, it’s not the interlock. 2 low works just fine.

Wuz thinks I forgot to cut off the shift rail and it’s hitting the doubler, which I also don’t think is the case. But I’m almost mentally geared up to pull this just to solve my curiosity.

I don’t want to. Still tempted to just wait for tear down and paint.
 
It's also possible that if the shift rail and fork were from different cases and mismatched that the fork offset is wrong and not letting it move far enough forward.
If all the parts are the same when it was in another rig and it worked properly with twin sticks something was assembled wrong.
 
FleshEater said:
Yeah, it’s not the interlock. 2 low works just fine.

Wuz thinks I forgot to cut off the shift rail and it’s hitting the doubler, which I also don’t think is the case. But I’m almost mentally geared up to pull this just to solve my curiosity.

I don’t want to. Still tempted to just wait for tear down and paint.
Click to expand...
I think it's something hitting the low range gears, but you could eliminate that by having someone spin the tires with the ass end jacked up and in gear and try to shift it manually into low with a screwdriver and see if it hits if you want to get curious without dropping cases.
 
Did you take a picture of the front of the rear case before adding the adapter? That will help determine if the H, N, L shift rod is sticking out proud of the case and hanging up on the adapter.
 
It’s not the shift rod.

I have this case in pieces on the bench. I can’t ****ing figure it out. It’s built exactly like the Marlin instructions say, and I still can’t get that driver’s side shifter to hit that third detent. This is pissing me off now.
 
2 86s said:
It doesn't look like a roll pin problem. The roll pin should be flush with the shift fork or slightly recessed which it looks like yours are.
If this case was run with the stock single J shift stick and you didn't remove the interlock pill between the shift rails to operate the twin sticks, that is your problem.
Click to expand...

That would only prevent 2 low

FleshEater said:
Yeah, it’s not the interlock. 2 low works just fine.

Wuz thinks I forgot to cut off the shift rail and it’s hitting the doubler, which I also don’t think is the case. But I’m almost mentally geared up to pull this just to solve my curiosity.

I don’t want to. Still tempted to just wait for tear down and paint.
Click to expand...


2 86s said:
Did you take a picture of the front of the rear case before adding the adapter? That will help determine if the H, N, L shift rod is sticking out proud of the case and hanging up on the adapter.
Click to expand...

Well, again, I ran these case for years with no issue. Not cutting the rod only stops you from shifting the crawl box in low and rear case in high. Rear case in low pushes the rod back away from the crawl box.

2 86s said:
It's also possible that if the shift rail and fork were from different cases and mismatched that the fork offset is wrong and not letting it move far enough forward.
If all the parts are the same when it was in another rig and it worked properly with twin sticks something was assembled wrong.
Click to expand...

All gear drive cases use the same rod inside the case, only differences are forward shift which are outside the case, you can just cut that off and it's the se as a top shift.


SKULLYOTA said:
the rail could be slightly bent? Any damage to the detent slots on it?
Click to expand...

I don't think so, they were all working fine. I don't think that would cause a hard wall either.


Looking at his pics over text. I'm betting the 4.7 gear got put on the output shaft upside-down. You can't see the teeth for the shift collar in this Pic.

IMG_5727.jpg


And the fork is up against the 4.7 gear in neutral.

IMG_20250320_171420.jpg


I had to Litterally turn my phone auto rotate off and flip my phone upside down to make sure it the angle of the gear wouldn't flip and it doesn't :laughing: so it would go together fine otherwise.
 
I see what you mean and if that's the problem unfortunately, it will require full disassembly to flip it.
 
Jeff nailed it. Damn gear was on backwards/upside down. Never built one before so I was bound to screw it up.

But I’m kind of glad I got to pull it out of the buggy. At least I know it can be done now.

So, I buttoned this up and wheeled the **** out of it tonight. Freaking LOVE it!!!! Never built anything like this and I just want to keep driving over stuff. :laughing:

No pics, no videos. Apologize. :flipoff2:

I’ll try betterer tomorrow.
 
xr-nut said:
A guy has a trip planned so he HAS to get it done :laughing:
Click to expand...

Yep. I’m going to wheel this a little more, finish up my skids and exhaust…then just bite the bullet and strip it all and paint it.

I also have to prep my 4Runner for Georgia and Florida at the end of April. Get a pop up camper set up on the trailer. And have the buggy ready to go for South Dakota in July.

These next 4 months will whiz by.
 
FleshEater said:
Yep. I’m going to wheel this a little more, finish up my skids and exhaust…then just bite the bullet and strip it all and paint it.

I also have to prep my 4Runner for Georgia and Florida at the end of April. Get a pop up camper set up on the trailer. And have the buggy ready to go for South Dakota in July.

These next 4 months will whiz by.
Click to expand...

You should build a little light wieght trailer to tow this behind the 4runner :grinpimp:

What's the dates in July? Want to try to meet up? It's only 13 hours from. Here and I want to check it out
 
YotaAtieToo said:
You should build a little light wieght trailer to tow this behind the 4runner :grinpimp:

What's the dates in July? Want to try to meet up? It's only 13 hours from. Here and I want to check it out
Click to expand...

Big Bertha is towing this out. I got about 600lbs. in spare parts and tools to carry.

Dates are 7-14 to 7-18. As of right now it’s Mike Honcho , xr-nut , xr-nut’s buddy, maybe Kansas Mark (Kungfoomasta’s buddy), and now maybe you. All are welcome. I just didn’t make an official ride page, because I wasn’t sure I could commit. Pretty sure I’m committed now.

My wife is going, xr’s wife, Mike’s whole family, so you can bring the whole family or whatever.
 
SKULLYOTA said:
Did you get the brakes figured out?
Click to expand...

Yeah, just had a little more air to squeeze out.

When I say I wheeled this thing, I put it to the test on a steep climb and 5’ tall rock, crawled a bunch of rocks on flat ground, etc. So the brakes, everything is good. I’m lucky enough to actually have some good wheeling in my front yard and back yard (literally).

Still working on air pockets in the cooling system. But they should work out the more I drive it. It’s an open system, so it should be escaping as it cycles.
 
Wipe all that moss off and try it again, brake clean will dry out the rock for extra grip. :laughing:

Unless you wheelbase out, it will crawl over it.
 
bad zuki said:
Wipe all that moss off and try it again, brake clean will dry out the rock for extra grip. :laughing:

Unless you wheelbase out, it will crawl over it.
Click to expand...

Just tried again. No luck. Going to try a different approach tonight. Got two big holes from the rear tires digging.

Also still overheating while in steep vertical positions. So annoying.
 
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