RWD to 4WD dummy transfer case

[Samistine]

I have a 1996 Geo Tracker 4-door 4-speed auto RWD.
I have a dummy transfer case and believe converting to 4wd would be a more straightforward process than getting a 4wd Tracker and swapping my good transmission and engine into. Plus my car has no underbody rust and is in great cosmetic shape. And there’s very few to no trackers being sold in my area on Craigslist.[/code]

[fixkick]

well, there are lots of things, to do this, the rear end of the 4speed, is not the same or its, main output shaft, then sure transfer case 96 + has new splines, to the rear.
the crossmembers,
the front axle and all parts related prop shafts, the front left frame maybe missing the front 4wd cross link mount.
see this, they moved everthing but using google site: (search tricks found it again, and now again...)

https://bbs.zuwharrie.com/content?topic=104321.0


the problem is the 4speed box, the main shaft, is not the same 2wd to 4wd, same on all 3 boxs (3sp/4sp/5sp all have longer main shafts exiting the main box.
the rear of the 4wd 4speed has the 4wd adapter, that mates the xfr case.
the 57b01 output shaft is 4wd only.
the 57bg0 ouput shaft is 2wd
the xfr case does not bolt to 2wd 4speed box lacking the added, 4wd parts in the A/T box.

[Samistine]

What is this adapter you speak of that sits between the transfer case and transmission. My transmission is already mated to a “dummy” transfer case.

Does this dummy transfer case have a different physical mating spec?
The diagrams I’ve seen appear to indicate that the dummy transfer case and real 4wd transfer case mate to the same transmission without extra parts.

I thought that was the whole point of using a dummy transfer case. So they could have a single automatic 4-speed transmission that would work in both RWD and 4wd cars.

[fixkick]

the 2wd trans and 4wd trans are not the same box.
each trans made has 2wd or 3wd extension housing, that fits the very unique transfer case.

seen here.
http://www.fixkick.com/tranny/slush/slid...age_3.html
and
http://www.fixkick.com/tranny/slush/slid...age_4.html
see 2wd extension here.
http://www.fixkick.com/tranny/slush/slid...ge_10.html


off our gallery,part number 3



here is generic photo of A44DE.
the suzuki parts book fails to show the 2wd version
do you have part 75>?

[fixkick]

the 2wd has tapered simple extension housing infact like all 2wd cars with a A44DE box , used on may toyota , even Mazda mini vans.
when they add this part#3 the box is now 3L-72LE.
the main shaft must be long enough to go past the new extension and last far far to the rear and the input spline of the Transfer case.
the 5 speed main shaft is actually shorter on the 4wd. (now the 4speed does this I do not know but the parts list show 2 shaft for the 2wd/4wd, (4speed)
and also know that seals can be landing on a different surface at the rear, 2wd /4wd. so... matters that.
you have no part 3. not at all,

[fixkick]

The diagrams I’ve seen appear to indicate that the dummy transfer case and real 4wd transfer case mate to the same transmission without extra parts.

this can be true, IDK, but never on any 5speed is this true.
on 4speed, I dont know IDK.
you'll have to check that out.
I am no expert at all on 4sp 4wd, not me, not at all , all I have are full books on it and full suzuki parts books, illustrated.
when you pull the wrong housing off the rear of the a44
and the connect the new one, the first issue will see is the rear seal match up the parts catalog clearly shows unique 2 and 4wd tail shafts. here. clearly but why is never said in any book.
then you next get to see if the transfer case fits the tail shaft spline. on the 5speed its too long, not possible.

the parts list even sHow the A44 main casing is different on the 2wd/4wd, not sure why but IS.

ITS ALL TO EASY TO MAKE ASSUMPTIONS., PLAN ON SURPRISES. FOR SURE DOING SWAPS.
THE PARTS CATALOG ACTUALLY FAILS TO SHOW 4DOOR WITH 4SPEED AND 2WD. (only minor 2wd foot notes)

[fixkick]

if you do have part3 and not part 75 but in the stead have an extension from part #3 to to the transfer case (a part that is actually missing in the most new, suzuki parts list)
then it may work
there is my best shot.

[Samistine]

Here are some pics, of my car, for those who are curious, of what I mean by dummy transfer case:




Full Album @ https://imgur.com/a/lg3BCFh OR http://web.archive.org/web/2019050115560.../a/lg3BCFh

[fixkick]

that may work !

the most hard thing to do is lookup 4speed box, output tail shaft variations and why .
very little info exist (5sp easy)4 not.