Suzuki samurai gearing for better mpg and daily driving

Samurai power vw

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Joined
Mar 3, 2015
Location
Roxboro nc
Hi, I have a built and restored samurai with the 1.9td conversion. I would like to know if you can help me find a higher gear ratio for my t-case? It is all stock except the Diesel engine and 31 inch tires and 3 inch aosp lift. It runs 3000 rpm at 65mph I would like to get that down to about 2600-2700rpm at 65mph. I really want a quieter ride and better mpg! I don't want a bigger tires or any more lift because it's a daily driver. Any help or other ideas would be great thanks
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completely different. The sami case is gear driven and divorced. The kick case is married and chain driven.

There is no higher range gear for the sami case. If you want to keep it, your options are taller tires, or axle swap for higher gears.
 
There are two different 5spd transmissions for Samurai. The 5th gear ratio is different. I don't recall the exact ratios. Even if you have the one with the less desirable ratio, swapping transmissions will most likely only help a little since I don't think the ratio difference is huge. Taller tires are really your only option.
 
Sigh Well then what kinda gears are available for the axles? And will my lockers go back after I change them?? They are ARB lockers

Stock gears are 3.73. No higher ratios are available, only lower. If I was you, I would investigate the 5spd deal first since transmissions are pretty cheap and easy to swap on Samuria's.
 
The transmission swap will only net you a decrease of about 3-400 RPMS on the highway. And that's assuming it's not already an early-model trans. The difference is in the fill and drain plug and 5th and reverse switches. You can't trust the shifters. I can't remember which carries which, though. I believe the early model fill plug is a square 3/8 hole and the late model has something like a 22mm hex head. Don't quote me, though. But if it's the Sammi I'm thinking about, it's probably already an early trans. That was a no-expense spared build.

Ultimately, though, you're really operating that motor in its sweet spot. VW diesels tend to like higher RPMs. The weight gain and increased drag from bigger tires will probably offset anything you'd gain in MPG. Might make it worse. It's got a broad RPM range, moreso than most diesels. You should be getting pretty good MPG with your current setup. I'm guessing you'll see between 25 and 32 mpg. don't expect VW mpg, though. You're pushing a lot more air with a Samurai. It's got the aerodynamics of a washing machine with the lid up. Plus, it's lifted, so that just adds to drag. It should do better than a stock Samurai, but don't look for 45mpg.
 
On a side note. I was wandering if someone could explain to me the purpose of the cold start cable? And how and when it should be used?
Just to update on the gearing: it turned out the drive shafts were out of phase. I turned them 90 degrees and it cleared up 80% of the noise and vibration that I thought was coming from the engine. Not so interested in changing gears now. Do I need to start a new thread when I'm asking different questions? Cause I got plenty. Thanks for the help guys.
 
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