Modified Samurai backing plate and new backing plate on axle

Old backing plate assemblyEvery Suzuki owner who works on his or her own Samurai will eventually have to pull the rear axles, whether it is to remove the 3rd member, to replace a broken axle, or to install a new set of axle bearings. I first learned of an easy conversion that simplifies this procedure while visiting Mild to Wild Suzukis for a trail run, learning that this has become a common modification among the Oregon 4-wheelers.

Required Suzuki partsOne of the nicest features of this modification is that it uses all Suzuki parts and is very inexpensive. The new backing plate is actually an SJ410 part, Suzuki part number 53821-80040 "Retainer, bearing outer" and can be obtained at just about any Suzuki parts dealer.

Tools and parts

SJ410 Outer bearing retainer(s) (53821-80040) Bearing retainer(s)
Rear wheel bearing(s) Rear axle seal(s)
Slide hammer (or other means of removing brake drums and axles) Local machine shop (or a bearing puller for removing the rear axle bearings and a press for installing the new ones)
Silicon sealant Assorted sockets and socket driver
Brake fluid

Disassembly

Beginning the disassembly processWhile this is not an overly complicated procedure, the number of parts that must be disassembled and later reassembled is very time-consuming. Since I do not own the tools needed to remove and press new bearings, I always take my axles to a local machine shop. After giving the shop instructions on what needed to be done, I was left with no more work than if I was simply having them replace the bearing in the usual manner.

Brake shoes and harware removed.You or your local shop must remove the old bearing and retainer, cut the hole in the center of the Samurai brake backing plate to be large enough for the bearing to fit through, and press on a new bearing with the SJ410 backing plate in place of the Samurai backing plate, making sure that the new backing plate is oriented such that the tabs on each corner of it face outward towards the wheel.

Wheel cylinder removed.Because you need to install a new bearing (which can also be ordered from any Suzuki parts dealer), the best time to do this conversion is when the rear bearings are worn out. I did each side about 6 months apart, but I could have done them at the same time.

Assembly

Reassembly beginsWhen sliding in the new axle and bolting up the backing plates, installation is very straightforward:

Backing plate and axle in place.The new backing plate goes on the outside of the original Samurai backing plate. The enlarged hole in the old backing plate will now allow the axle and bearing to pass through, making this the last time it has to be removed and the brake system bled.

Brake hardware and shoes reassembled.As with the normal procedure, properly seal the backing plates with silicone and reinstall and bleed the brakes; the procedure is complete.

Impressions

Total cost to me was $45 for the bearing, seal, and retainer from Petroworks, $10 for the SJ410 backing plate from Mild to Wild Suzukis, and $30 to my local machine shop for their ½ hour of work. The only cost in addition to a normal bearing replacement job is the $10 for the backing plate.

The advantages to this conversion are numerous. For example, if the differential needs to be removed, sliding the axles out of the side gears is now a quick, simple turn of a few bolts. When another axle bearing goes out, the brakes will not have to be disassembled. If axle breakage is a concern, spare axles can very easily be carried and stored, thanks to the much more compact backing plate. Trail repairs are significantly simplified, and above all, time and frustration are avoided every time you work on your rear axle.

--Geoff Beasley