im not sure at what step you are at, bell off, ? and rear extension off? and you are doing the final vertical split? is the front pilot shaft collar off, all 8 bolts.
this TOP case IS glued together with Superbond 1211 (aka as Suzuki bond) day 1. and will be hard as nails after 20 years.
the TOP case DOES have built in pry points.!
I always look for those, (motor cycle guys learn this fast... or leak city) and find them fast. almost all cases have these special pry bosses.... dont not try to jam metal in the seams. that wrecks all aluminum cases fast.
see photo below from the FSM page, this page is very clear on case split......
the exception is the suzuki engine oil pan and the RTV there, and the special Suzuki spitter tool, wedge, covered in plastic. (i use plastic tree cut down tool , those yellow wedges (old days were steel) and make great pry tools, safe......sold in all good places that sell china saws ) the are Poly wedges, but i never use them on transmissions... just wood blocks and rubber hammers.... never hit steel against steel.
off my 5sp page, rebuilders. is this link below see page 8 and 9.
http://www.acksfaq.com/pdfs/sidekick_dri...manual.pdf
![[Image: 3_28_05_15_11_58_55.jpeg]](http://www.fixkick.com/bbs2/Suzuki-bbs/gallery/3_28_05_15_11_58_55.jpeg)
see that PDF< tell us where you are in that book.
what page, what step..
"Spacer case" i missed that it showed up as i typed,,,,,,
i guess the rear 4wd adapter is stuck>? (the word rear helps me greatly)
so both shifter top part is off and the base shifter extension is off? extension housing? of top of tranny , exposing the hidden bolt on top?
you are at step 3 , page 8 , transmission unit...?
it only says remove housing,, terse.
all 1ing?2 bolts removed on that hous
the housing is not full of GL4 , on a running car, 4WD, it has AIR in there, so if you do damage it , do so on the top,, (it must come off evenly !!!!)
the case is not glued on, if it is ,someone had a brain fart.
the bottom of that case is a vent hole, see it? that is the tell tale hole that the 2 seals above are leaking GL4, (box or xfr seals) see my slide show for that hole.
look for pry bosses..!! this is always rule 1, on all aluminum casings.
if none, then use wood, and hit the wood with a hammer , round and round taking full patience.!!!. it will separate. after all there is nothing there hold it in, its just a spacer housing.(and guide pins !)
the top of the tranny step is more hard,
the pry bosses are there.
also there are wings it this front of case, seen here. if you must pry , if f the special center case spilt bosses are not enough. but should be...
those wings are prime targets. as they have no seals on the outer parts.... see that???
see those wings here bottom left. and the GUIDE PINS< (the pins can jam if you dont take it off evenly) true on all cases with PIN guides.
![[Image: prob2.jpg]](http://www.fixkick.com/tranny/images/prob2.jpg)
see me here add this housing after its off, I am checking my seals and bearing fits, and if there is no end to end jamming, well before final assembly!!!!!. .i am here
as you can see , nothing holds it but 12 bolts.
also see my DIY free, magic tools ,here, gear pullers, and chain tricks....
see this slide show. off my 5sp rebuilders log, the photos make it clear what holds what..
frame 20 shows the vent hole , mentioned above. air filled casing it is...
frame 3&4 shows end of case. and see that gap there, and that only pins and 12 bolts hold it.?
http://www.fixkick.com/tranny/images/html/image_3.html
see the case just split and NO GLUE HERE, and see the 2 guide pins, those pings (hollow and large) must not be allowed to jam, by attempting to remove case cockeyed.......
![[Image: T4day2%20%285%29.jpg]](http://www.fixkick.com/tranny/images/images/T4day2%20%285%29.jpg)
in my case the PO caused the transfer case to not want to ever ever come off....
i used a huge 4wd chevy truck and a huge 24" fir tree, to separate this casing.... due to spline jam up... big time..
but in your cars the transfer case is already off. per normal.
i cut a hole in the center case. to look in side, and go, OMG, what is that, a home made tail main shaft, with a dremel tool.. what a monster he was..... amazing fact.
I had 2 trans, and 2 transfer cases, allowing me to make one good system. like new.
this TOP case IS glued together with Superbond 1211 (aka as Suzuki bond) day 1. and will be hard as nails after 20 years.
the TOP case DOES have built in pry points.!
I always look for those, (motor cycle guys learn this fast... or leak city) and find them fast. almost all cases have these special pry bosses.... dont not try to jam metal in the seams. that wrecks all aluminum cases fast.
see photo below from the FSM page, this page is very clear on case split......
the exception is the suzuki engine oil pan and the RTV there, and the special Suzuki spitter tool, wedge, covered in plastic. (i use plastic tree cut down tool , those yellow wedges (old days were steel) and make great pry tools, safe......sold in all good places that sell china saws ) the are Poly wedges, but i never use them on transmissions... just wood blocks and rubber hammers.... never hit steel against steel.
off my 5sp page, rebuilders. is this link below see page 8 and 9.
http://www.acksfaq.com/pdfs/sidekick_dri...manual.pdf
see that PDF< tell us where you are in that book.
what page, what step..
"Spacer case" i missed that it showed up as i typed,,,,,,
i guess the rear 4wd adapter is stuck>? (the word rear helps me greatly)
so both shifter top part is off and the base shifter extension is off? extension housing? of top of tranny , exposing the hidden bolt on top?
you are at step 3 , page 8 , transmission unit...?
it only says remove housing,, terse.
all 1ing?2 bolts removed on that hous
the housing is not full of GL4 , on a running car, 4WD, it has AIR in there, so if you do damage it , do so on the top,, (it must come off evenly !!!!)
the case is not glued on, if it is ,someone had a brain fart.
the bottom of that case is a vent hole, see it? that is the tell tale hole that the 2 seals above are leaking GL4, (box or xfr seals) see my slide show for that hole.
look for pry bosses..!! this is always rule 1, on all aluminum casings.
if none, then use wood, and hit the wood with a hammer , round and round taking full patience.!!!. it will separate. after all there is nothing there hold it in, its just a spacer housing.(and guide pins !)
the top of the tranny step is more hard,
the pry bosses are there.
also there are wings it this front of case, seen here. if you must pry , if f the special center case spilt bosses are not enough. but should be...
those wings are prime targets. as they have no seals on the outer parts.... see that???
see those wings here bottom left. and the GUIDE PINS< (the pins can jam if you dont take it off evenly) true on all cases with PIN guides.
see me here add this housing after its off, I am checking my seals and bearing fits, and if there is no end to end jamming, well before final assembly!!!!!. .i am here
as you can see , nothing holds it but 12 bolts.
also see my DIY free, magic tools ,here, gear pullers, and chain tricks....
see this slide show. off my 5sp rebuilders log, the photos make it clear what holds what..
frame 20 shows the vent hole , mentioned above. air filled casing it is...
frame 3&4 shows end of case. and see that gap there, and that only pins and 12 bolts hold it.?
http://www.fixkick.com/tranny/images/html/image_3.html
see the case just split and NO GLUE HERE, and see the 2 guide pins, those pings (hollow and large) must not be allowed to jam, by attempting to remove case cockeyed.......
in my case the PO caused the transfer case to not want to ever ever come off....
i used a huge 4wd chevy truck and a huge 24" fir tree, to separate this casing.... due to spline jam up... big time..
but in your cars the transfer case is already off. per normal.
i cut a hole in the center case. to look in side, and go, OMG, what is that, a home made tail main shaft, with a dremel tool.. what a monster he was..... amazing fact.
I had 2 trans, and 2 transfer cases, allowing me to make one good system. like new.
http://www.fixkick.com