5-Speed Manual Problems

[cdfurst]

Now I'm thinking about buying a different xfer case. The one I found is from an 3speed auto. Will an '89 automatic xfer case fit a '96 manual tranny?

[fixkick]

then the secret ball trick
the trick is to remove easy part serially, if you attempt to pull bunches of parts, at once the locking ball jams.
ball 17
off my transfer case page

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that is a good question
'89 automatic xfer case fit a '96 manual tranny?

that is hum dinger. jumping from gen1 to 3.
hummmmmmm
the tranny dont matter all 4wd case are same per gen. regardless of 3/4/5 speeds. (2wd differ. story)

the p/n vary

3 gens and the queer early 89, i can go there, for early 89s.. have serial cross over,
89 gen. same cases as the 96-98
95 has this unique rear case. ? in not sure why and A21 CENTER NOT A01. CENTER










at first blush yes.
let me look that up.

[cdfurst]

OK, so this '89 auto xfer case WILL fit the '96 5speed???

[fixkick]

THE P/N FOR THE 4WD TRANSFER CASE DOES NOT change with tranny, not at all, the transmission has the adapter built in the each trans. tail end.(case)
i check rebuilders and most have 3 gens of transfer cases.

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there were some early 89s built in japan actual and have some very odd parts.

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but the 89 xfr case has wrong output splines splines
all 96's have new spins. at end of transfer case.
but most transmissions, fit all transfer cases we think.
in 1992 some parts like bottom mounts changed, but is details, like thread mounts or not.
we see a 91 engine in 96 kick. 5speed.
suzuki is no help here, nore is HAMMAND data bases for swaps. at wreckers it tells you each is to match generation. but we do know , some of the changes are minor.

you must have a 96 or 98 transfer case to fit your RAMCO, cut out. 96 yoke.
or most find a good 96 main shaft and move it to older box.

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the 89 xfr case does fit all transmissions, i think. the mount flange and spline match.
the 89 trail shaft is not good for your rear yoke.

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car-parts dot com
clearly shows (Hollander checks?) that 89 xfer case fits up to 95
and if you select 96
only goes forward. to 98
so its clear there is some brains working there at car-parts.com.

$$$$$ , ive never looked but would be fun just once.
http://hollanderinterchange.net/

[cdfurst]

Okay, you were correct about all transfer cases fitting all trannies. Got the tranny and transfer case put together and was about to stab it when I had a thought. Now would be the time to drill the ports for an external pump for oil circulation while towing. I took the old transfer case apart to see where the best place would be for these ports. That's when I had another idea. What would be wrong with drilling and tapping a 1/8" pipe thread hole, in the aluminum case, about 1-1/2" above the fill plug and taking the oil level up about 1-1/2". The way I see it about 1/2" of all the bearings and gears would be sitting in oil at all times. I'm also thinking about either mixing half 90 weight and half ATF to thin the oil down, or even run straight ATF. I do run Royal Purple in everything I own, so it would top quality oil. BTW, purchased the Royal Purple 90 weight yesterday, $20 a quart.

[fixkick]

only issue i think is oil might foam up,, overfilled. running
but towing be ok. seems to me. nice ideas. all.

[cdfurst]

Finally got my Tracker finished up last night. Only problem I've got is the speedometer not working. I put MY speedometer gear in it because the transfer case I bought came without one. Must have been a different gear ratio because mine is different and doesn't even touch the output shaft gear. I'm guessing that these things are color coded??? I had green gears before the swap. The gear that is on the output shaft now, and the one I need to match is blue. Not to worry about calibration. I am running the Jetta cluster which is electronic. I installed a pulse generator on the transfer case where the speedo cable goes, and I have a pulse converter so I can calibrate it when I get it working again. Am I correct about the color codes and where can I get a BLUE gear?

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Also, cannot find where to post a profile photo. What are the steps?

[fixkick]

yes there are many gears, one for each tranny, and axle ration and engines. (some engines run taller gears , due to torque/rpm profiles.
only suzuki sells this gear.
and needs tranny trail shaft cover off, or xfer case. off.
the suzuki EPC (catalog of parts ) does not show color, one more Suzuki secret.

here are all stock sidekick gears. on my speedo page.
http://www.fixkick.com/sensors/speedo/un...tml#ratios

who knows, might this be and X90 trans? i can look it up. all suzuki's that use this same xfr case.