In Brief

A transfer case mounted replacement emergency brake for those who've converted to rear discs or installed non-Suzuki axles like Dana 44s. The kit comes in two 'flavors' to fit the different size output flanges found on Samurais of different model years.

Background

Given the engineering requirements, I was actually surprised to find that anyone has produced a transfer case mounted emergency brake for the Samurai. There's little room available, there's a host of problems to solve in making the thing work, and there's the added problem that the Samurai's transfer case mounting system can be prone to mushy or torn rubber mounts and bent mounting arms.

Many people converting to rear discs have resorted to line locks, which, while effective, are illegal for this purpose in many states. Line locks also require routing new rigid line into the passenger compartment, a job many don't want to undertake. Finally, they won't do you a bit of good if the reason you need your e-brake is the failure of a brake line.

You could use disc brakes having a manufacturer-provided emergency brake, but then you're talking using a lot of non-Suzuki parts and complicating your maintenance requirements. You'll also have to figure out how to adapt the manual cable system from another vehicle to your Zuk.

Spidertrax designed this kit as a means of providing an emergency brake for people using their Rear Disc Brake Kit. Those with non-Suzuki rear axles like Dana 44s will also find it useful in providing them with some sort of emergency brake as well.

Installation

This kit is easily installed by a backyard mechanic. The installation text is clear and detailed. Although the pictures for this particular installation are not quite as good as those found in the instructions for the Spidertrax Rear Disc Brake Kit, they didn't cause any real problem. About the only confusing step that could really benefit from a better picture or diagram is that for the order and position of the new polyurethane transfer case mounting bushings.

The kit consists of a transfer case output flange-mounted disc that is gripped by a mechanically actuated caliper. It uses the stock Samurai brake handle and cable and provides through-bolted polyurethane transfer case bushings to replace the stock Samurai t-case rubber mounts. The proper grade hardware for the various components--and even an Allen wrench for assembly of the caliper mount--is included.

The most difficult thing you'll encounter in installation (and it's not very difficult at all)  is removing some of the left-over parts that hang from the stock e-brake cable and that are no longer required. You'll have to figure out how to slip them off or cut them free as you proceed.

Proper adjustment of the e-brake caliper is the most critical step. Closely following Spidertrax' instructions at this point will prevent premature wear-out of the brake pads.

Installation details and additional pictures are in the Tech section.

Impressions

The e-brake provides great holding power. I tried the brake in a variety of parking positions prior to leaving for Moab, and then on the trail at Pritchett Canyon. The Spidertrax E-brake had no problem in holding the truck in any situation I encountered.

You'll note that there's a very slight rocking in the position of the truck as you first apply the brake. This is due to the fact that there's some 'wind-up' that occurs in the driveline as slack is taken up and is completely normal.

I haven't noted any unusual vibrations or other problems arising from the change in transfer case mounting. In fact, the new mountings are a plus as far as I'm concerned, as I won't be dealing with torn rubber mounts on the trail any longer.

The e-brake disc is exposed under the vehicle and requires protection. Those running without a belly pan should plan on installing one and fabricating a short rearward extension to it in order to protect the lower edge of the disc. The brake clears the commonly used Con-Ferr type skid plate by about ¾ of an inch. You can reach the components of the e-brake while the skid plate remains in place, so maintenance won't be a headache.

I had the 'opportunity' to be the first to test one of Spidertrax' design objectives while in Pritchett Canyon. A downpour resulted in our deciding to bag the rest of the trail and reverse course. This meant we had to take a large step up on the way out of the Canyon, an obstacle that usually is taken down. Between having a generally lousy day--as far as my wheeling ability was concerned--and wet, slippery conditions, I ended up slipping backwards off the step. The rear edge of my skid plate took the full force of an encounter with a chunk of rock sticking out. This pushed the skid plate forward (as the J-hangers slipped on the frame) nearly an inch and a half and caused the skid plate to catch the e-brake disc.

The disc performed as designed and bent, preventing damage to the output flange or the transfer case. It wasn't difficult to perform a quick trail fix after getting the rest of the way out (about ½ mile of easy 'road') and then a more permanent work-around so I could wheel while waiting to hook up with Eddie or Tom for a replacement disc.

I noted two things as a result of this incident.

The first isn't a 'design fault' at all, at least not as far as Spidertrax' kit is concerned. I'd recommend switching from J-hangars to fixed mounting studs for your skid plate if you'll be using this kit. The J-hanger mounting method for skid plates has always been a concession to ease of installation in the first place; in this configuration it becomes a liability. Making the rear extension to your skid plate about two inches longer than necessary (and than I made mine) would also prevent this type of problem if changing to a fixed skid plate mounting is not possible for you. You could also weld some front positioning tabs to the skid plate to prevent it moving forward.

Second, the motorcycle-chain-type master link used to connect the stock e-brake cable to the actuating arm of the caliper is a PITA to remove. I understand why this link is necessary as well as why it was a natural response to the design problem presented, but the general layout (something beyond Spidertrax' control) makes the position of the link extremely awkward when it needs to be disassembled. As anyone who has owned a chain-driven bike can attest, the link's clip is also prone to fly off into never-never land when you remove it. Carry a spare. I've talked with Tom Kingston about it, so perhaps the ingenious Spidertrax design team will come up with a more easily operated link.

Spidertrax E-Brake Kit is available from Spidertrax distributors for US$245.00.

I'm happy with the results of this installation. The well thought out design should simplify maintenance. And, since the brake provides much more positive holding than the old rear drum e-brakes (which had almost never worked well on my truck), I'm no longer concerned about Suzushi rolling off on a trip on her own when I'm out of the vehicle.

--Scott Gomez