When you install lower gears in your transfer case, it is vital that you correctly shim the shafts. This will not only extend the life of your expensive gears, but help them to run cool and quiet.  Shims in a Suzuki Samurai transfer case are installed to adjust lateral clearance (end-play) for the input shaft, output shaft, and counter shaft

• Input Shaft Shims: Installed in the center housing or rear housing depending on the specific rebuild kit and measurement requirements, typically placed against the bearing to control input gear mesh. 
• Output Shaft Shims: Installed in the rear housing against the output shaft bearing to set the correct thrust clearance for the main output gear. 

To determine the exact shim thickness and placement, you must disassemble the case, measure the gap between the case halves and the shaft lengths, and calculate the difference. The target case gap between the center and rear housing halves is typically 0.36mm to 0.45mm (0.014" to 0.018") when squeezed together without tightening bolts.  

Shims are available in various thicknesses (e.g., 0.1mm, 0.3mm, 0.5mm) and are sold individually or as a full set:

• 0.1 mm Output Shaft (29147-80050)
• 0.3 mm Output Shaft (29148-80050)
• 0.5 mm Output Shaft (29149-80050)
• 0.1 mm Input Shaft (29117-80050)
• 0.3 mm Input Shaft (29118-80050)
• 0.5 mm Input Shaft (29119-80050)