Fixing the Shifting Issues

[fixkick]

they dont know whats in your car ,nobody does, it can be the 3rd used trans.?

the trans has a serial number and year code, did you look for it?
W code is 98,

the bearing #8 on the suzuki parts list is same bearing 89-98,2wd and 4wd both and same in SPORT version.
so im not sure what GM box is there. not at all.
that same link, i go to the case page, and it shows only 1 case. pn/ odd huh, how could that be true. 5mm bore ,is a larger case .

[Vitalie]

Drive line issue.: http://youtu.be/R0Q-hyh6vzk
I got this video of the rear jacked and wiggled the wheels while in 1st gear. There is a Loud noise as you can hear. I believe this is what I hear when I change gears. The excess play generates a uneven transition of power from the engine to the rear. Resulting with a kick and loud bang.

The shift lever moves: http://youtu.be/CI4Dv6NXnv8
In the second clip is the behavior of the shifter lever if you play with the gas pedal on off while rolling in the 5th. I think these 2 things are related.

Is this normal by any means? It annoys the he'll out of me. What do you guys think is actually going on here.

Thanks

[fixkick]

i looked again all videos.
the trans play in 4th gear is too much, seems to me, 10-20 % there at tail shaft the clutch is new so the front tranny pinion is rock stable.
when disk off , most high mileage kick 5 speeds, i see huge front pinon spline damage. and if so, this play seen in the video is normal.

then the rear wheel spin, that play is normal,

the pumpkin pinion (pig) seem excessive. but the tires were off the ground fooling me,

the stick moves any time you make large torque, like letting the clutch out fast, (called torque reaction , Newton, laws)
but not at steady cruise, its steady 30hp and there is no reactions.

[Vitalie]

If this tells somthing I was doing it on both wheels and it acts the same.

I am pretty sure the rattling noise is coming from the transmission I was clearly hearing it, thats why I focused on trans as the sounds get louder getting closer. (I was under the impression of gears noise)

I will check more, unfortunately is my daily driver, but I can be very gentle to her till we fix it.

I checked the ujoints at propeller when I did the clutch and there was no play at all.

checked the diferential fluid was full and clear.
Thanks

[fixkick]

i dont know what car status is in all tests and all videos

in gear, , and all videos with no tires in view, are they up or down.

TRANNY. NOISE, if it is. (only you can hear it. using a stethosope. mech or electric.

if in 4th gear , that noise can only be a few things.
bad tranny bearings. (horrid bad)
bad front pinion, front dogs, very warn , 4th gear or its matching hub.
or the clutch spline (same part as pinion above) is horridly worn, my last 2 were, i had to buy a new one., at $175 a pop.

[Vitalie]

Tail to propeller test: http://youtu.be/Xy0_X01tmFA
here i did the test to the property to tail shaft. The wheels are on he ground this time and in 1st gear.
You can hear that it makes the same rattling noise coming from the extension case. The ujoints look solid.
Preliminarly I think is the extension case ore maybe more internally.

Also the splines are in great shape. I remember I checked when pulled the tranny out.

Thanks

[fixkick]

im deleted this , its all speculative.
only the tests done later are a clue.,.

yes , man handle all U-joints and see if they have play first. this is easy.

[Vitalie]

so the spine is loose, why not put hand on the yoke, all way forward and move it, in the wrong directions, (not turned) does it move, its bad. its only supposed to turn, !
possibles:
1 bad yoke spline,
2 bad spline,
3 bad both.
do you know how to check a spline?
well since the front of yoke has shroud, then its impossible to see the differential movements, but can see lateral, but you never did that. yet. put hand there and move it 90degrees, (to the side) it must not move. or up and down, it must not move. use strong hands , say with 50 lbs of force, (man handle it. is the word, end the twisting we get that.)
but you can take it off and check it. sure can.
or just buy a new yoke, and try it, be like 100x less that a new tranny.

ill give you the factory p/n now.
98 5sp, 2wd, 4dr

the shroud is to keep the grease on the spline,
the spin should have been kept, greased, but they all fail.
27140-60a51
fits only 4dr and only 5speed

this car is easy, it fails in hand
try the ones that only fail at 70mph .... no fun. (but have the cure)

27140-60a51
http://www.lehmansuzukipartsonline.com/p...eid=216897


less, you can shop at all suzuki online and find best price using my number, note its missing on their drawings, they are lazy.

https://monsterfactoryparts.com/parts/19...eid=217481

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its bad yoke, it have it off and in my hand and inserted to the tail and feel it,
and look at both ends. the shaft and the inside spline of yoke
see that WHERE, see those steps.

shaft -- --------___________ see this step, on the shaft, that means END OF LIFE for shaft.
now the bore of yoke
___________-------------- see that step, same, im betting the joke is bad. but looking counts.
and feeling it.
it's supposed to be a slip fit, that means no SLOP.

usually the yoke is softer steel and wears first
the shaft is heat treated and maybe even forged, metal, (2x stronger)

I test it again and this time put as much force as I could with one hand. It dose not move up or down nor left nor right. it dose however move just a tiny bit back and forth, but it dose not rattle, very very tight.

all wheels on the ground. In neutral the movement is the biggest. In gear 1 2 3 4 5 R and parking brake on. it rattles but less than in neutral. If just In 1st or R no parking brake. there is no rattle at all. but also the car rests on transmission constantly.

I remember now that on the yoke I notice that there is like on spline is missing. But it looked like an alignment design or something Not damage.
   

Maybe I can take it down this week and test take some pictures.

[fixkick]

that is a balance key, all parts here are balanced, that is why it says in fsm book, put match marks on the joints before dis-assembly.
ignoring that , may cause the horrid noise at high speed,.
back and forth is normal that is the normal spline movement.
car rests on transmission, not sure what that means.
finding the cause of noise can be easy to hard.
but id watch that yoke spline first, and check it carefully first.

[Vitalie]

Ok I took the propeller off to do all the tests.

Yoke only to tail shaft: http://youtu.be/ZITiQO6qa98
Rear main shaft test for noise: http://youtu.be/cu6JzB8D4ME
Differential test for rattle an wear: http://youtu.be/O7wmAL0fwZY
Yoke to transmission test: http://youtu.be/nZan1AZ938o
Yoke examination: http://youtu.be/4Og7ruy65Mk

So you can see that there is excessive play in differential and some in the transmission case. The yoke and the joints do not have play.