5-Speed Manual Problems

[cdfurst]

Driving along this morning about 65 MPH and 5th gear just stripped out. Had to downshift to 4th and drive home at 60 mph. There are plenty of 2WD trannies around. Question is, will the transfer case fit on a 2WD tranny after removing the tailshaft housing???

[fixkick]

no not ever. the main shafts are totally incompatible.

I have nice photos of a goffy guy that tried, (band sawed cut with drimmeled to heck)
seen
http://www.fixkick.com/tranny/images/rea...283%29.jpg
did you replace the $4 plastic on the shifter tip. bingo, i bet. they all die soon and often. part ID #27 see below pages
you can also shift it with no shifter, handle, see my 5speed page. this proves the trans is ok. easy.
5th and reverse use same shift rail.
move part ID 30 by hand (use a screwdriver or large drift pin to shift it by hand , shifter off) see drawings.


can be done 2 ways, extension housing on or off
http://www.fixkick.com/tranny/5speed-rebuild.html#Test

do not pull tranny until both tests are done. (plastics 1st)

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what he did was , forgot the seal on the 4wd is in front of shaft.
on the 2wd, its rear end, so it leaked like NIGARA falls. GL4 lube, UNSTOPPABLE. and then burn up 2 gears.

[cdfurst]

Oh yeah, I just replaced the plastic pieces 3 weeks ago. It's not slipping out of gear. There is NO DOUBT, a gear is either stripped of it's teeth, or a bearing has come apart. Have you ever hear of 5 gear stripping like this? I'm getting ready to pull the tranny now. BTW, I never tried reverse since this happened. I just pulled it in the garage and shut it off.

Okay, I just went out and tried reverse. Bingo, it does the same thing in reverse. I guess that means I've lost the bearings on that shaft??? How hard are those bearings to replace and can I even get them???

[fixkick]

ok, one more deal.
the right side of tranny is this large bolt. its must never be removed
bingo......

in a jiffyboobs joint they guess this is a filler plug bam, killed your tranny, it must be calibrated at install time. for gear lash.
see upper right gear here,?


if they remove the bolt the whole thing falls, and will kill reverse and 1/2 time destroy that huge rear 5th gear.
seen to far right.
but then again, bad shift forks?

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pin 7 sheared?



the only tricky part of the whole trans are the 2 well hidden tiny balls that lock up the works. ask.

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id drop the trail shaft and cross member then let it tilt down , an off the extension housing, to see.

then i push this left shift bar.
if it feels dead, ? its pin 7 sheared.


im doing this now, see me
im on wrong gear, move to left side.

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you can feel the synchro dog in , in 5th, if not the pin is snapped.
and reverse are non synrchro's and will hate being shifted not running and foot off clutch, (all stick drivers know parked that reverse is funky this why, even my new jeep does that)

by hate, i mean the reverse square cut gears, will not want to mesh, this trick allows you to feel if the rail works, if super easy, just by pushing the left rail back.? that is sign one, next is 5th feel.
the rods work opposite of lever end.
forward is back.
leaf is right. no big deal.

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be sure to check that rail fails to get a gear or jumps out of gear, seeing the rail bounce back is one more sigh.
could be bad detent ball.or is spring.

[cdfurst]

Great info and thanx for the quick reply. This thing has never seen the inside of a JippUlube, nor will it ever. I do all my own lube stuff.
If it's the pin sheared, tranny still has to come out, right? I can't see getting to any of this with the floorpan in the way.

[fixkick]

yes, the case must be split to reach the pin, bell off. tranny out
that is why i recommended the feel test. with first with just shifter out, then extension housing off.
it might be and issue with the extension housing (shifter pit parts) more pins and do dads.

[cdfurst]

Next problem. Finally found another complete tranny/xfer case. Got it home and cleaned it up. Getting ready to install it and realized that it has a different output shaft spline count. Not sure what year the tranny I had was, somewhere around '91. I do know that the tranny I just purchased is a '96. Seems if it had been one year older, everything would fit perfectly. This is a huge problem because my rear drive shaft is custom made with CV joint (very expensive) and slip-yoke eliminator. I'm not even sure they make a slip-yoke eliminator for the '96 and up spline. Can't seem to find one. Not sure why they would only make one for the earlier spline???

[fixkick]

yes, spline changed in 1996


Quote the forums... Transfer case issues.
"The 89-98 tranny is mostly the same form factor, it fits but there are exceptions:
The transfer case changed in 96 with new out put spline changed. (and for sure prop shafts)
Input is the same. to XFR case. input spline count is 23 ,BTW.
All t-case (transfer case or xfr case) input splines from 89 to at least 98 are the same size and count.
T-case output shaft splines are the same from 89-95 (26 spline) and from 96 to at least 98 they are 16 spline.
The output shaft size is 30mm (1.81"). on all."

this one is 96?

[cdfurst]

So, how hard is it to change the output shaft. I should tell you, I found out that I've been running the old Xfer case dry of oil for a year and did not know it. Smooth forgot to check it when I built this this thing and put it in service a year ago. So I suspect the inside of the xfer case is TOAST. But I'm sure the shaft would still be OK to reuse??? Also, just found out that they DO NOT make the slip-yoke eliminator for the course spline. What to do???

[fixkick]

there are more pre96 transfer cases, in the wild. (suzuki sales dropped like a rock after the Consumt'n Reports, mag article.
its easy to find this out, just look at P/N of the 95 box. to 96.
only 10 parts touch that shaft.

only 2 wont fit. the speed driver gear will not fit. and the chain drive hub is 16 splines.
all other parts fit all 8 fit.
and have same partnumber. including all bearings and gears. and drive hubs.
and one bush. and seal.

how much wear is on that shaft?, only eyes and feel can tell
a new shaft has pn
1995 of>>>>> 29141-60a00 at $115
http://www.lehmansuzukipartsonline.com/p...eid=216897

btw, 2
Suzuki changed, drive chain, and both hubs, mid year 96.