This page might be used to pull ANY transfer case by self, see RED comments. (the FSM states just that) I typed this after doing it twice (91 and 97' year) This is all mostly redundant to the FSM page 32+ steps 1 to 33 My below words, are an adjunct to these offical pages. Do not replace the clutch, until the clutch cable is replaced and adjusted and the 1 inch rule validated and the still clutch fails fully disengage. Bad clutches can slip, drag, chatter, jam engaged permanently, make noise, bang gears, and grind gears. The clutch will not cause the gears to jump out of gear, nor jump to neutral. (bad tranny) Do not change the clutch actual, until the 2 plastic parts are replaced on the end of the gear shift lever. (can't get into gear, engine running and not?) Tools ?, special, jack stands and wrenches are required, but a tranny jack real, makes it more easy and vastly more safe. (if pulling the transfer case alone or in sequence, muscling out may work, no jack) Some folks just pull the engine and transmission all at once. (way less on your back pain, on cold concrete , and less cussing, no need for tranny jack, only and engine lift ) For noobs (not a dig!), the clutch is located inside the bell housing in front of the engine, and the transmission must be ,detached from the engine to service any clutch parts, inside. It takes 4 hours in, and out, first time (8 total) , or less if you have very good tools (and vehicle lifts) (4 to 8 hours total, based on skills and tools and luck; luck means, no stubborn rusty parts, that fail to remove or are so bad they are non serviceable and now a wild goose chase, for finding rare Suzuki parts. ) Changing out (swapping in) a new clutch. Some people have a nice engine puller (chain hoist or engine cheery picker lift) to make clutch changes easier, they just pull the engine. How to remove the transmission varies by your shop, garage, if you have one at all? or doing it at the road side curb? There are 4 ways to pull a clutch, depending on shop and tools. Below is the JACK stand way. ( the 4 ways are: stands, pits, lifts, pull engine) The below will help. Garage stands way, no pit, no whole car lift, just jackstands x4 and one trolley jack or a rented, transmission jack is best. or like I have, this adaptor. or DIY:
Inspect the transmission front bearing by wiggling the main input shaft up and down. No play, and no seal leaks in tranny ,right? No heavy damage to tranny input shaft splines , and pilot bearing tip ! This play, should not happen nor should signs of GL4 lube drip, from same shaft. (or you need a new bearing or seal in tranny) The Distributor 0-rings on casing, love to leak and fill the bell and clutch with motor oil.(and looks to all the world like engine main seal leaking and is NOT) See oil on top of Bell , "BINGO" see vent on top of bell, oops, ingress point. BACK to the FUTURE: Reverse the above procedures. but use the clutch guide tool seen below, to install the pressure plate. (DIY and Home made) Trick 1: Make a pair of guide pins, by buying long bolts, that fit the top 2 bell mount points. (yes, they are metric, take old both to store, buy them 2x longer) Take the 2 top original bell top bolts and buy 2 new same mm size ones , 2 times longer. then cut off the heads and radius the cut. Next cut a screw driver slot in the end. with a hack saw. or file ends square, for later retrieval. I then screw said DIY guide studs into the block at the 2 top positions of the bell mounts on the engine block. Now the tranny has 3 POINT guides, 2 guides plus the pilot shaft ! Install the tranny to bell housing bushings and center plate. the bushings are at 1PM and 7PM via drivers view. See them? Put it all back together, as you started and adjust the clutch free play. See the first link at top of page for those details. Add GL4 lube to both gear casings. Failures and pit falls:
The pilot bearing comes out , via : grease gun tool kit for pilots,(uses hydraulic force to OFF IT) , remove flywheel and it from behind it, or use a slide hammer with included bearing puller. Adding new seals in the distributor base, and dizzy shaft o-rings.. then new "VITON" Seal in rear main from "FELPRO", that wood block is even mentioned in the Suzuki FSM. The 5speed BELL, has a vent, that lets DIZZY oil leaks, run right where those 6 Phillips screw are dead center........ Look carefully if the main leaks, the flywheel MUST get wet. (a top clue) This main seal is not prone to leak, it's huge and robust. Photo1: Next is Fly wheel, with new pilot bearing. ("Timken") Photo 2: Last is PP, the pressure plate, the disc, will not go on backwards, good news. Photo 3: The vent below , will magically suck in all engine oil from the 2 distributor leaking 0-rings or the Dizzy housing bases seals or the 16v rocker rail seals or OMG, a bad valve cover gasket at the rear (not doing 60k tuneups caused) My buy parts page (see index on 0-rings) shows how to get "Viton" seals that will last the life of engine. Do not remove the lever seen below on the right. (unless you see its index markes, or make your own !!! Photo 4: Below, rear looking to front , see transfer case and drain plug (10mm square drive) do not use 3/8" socket drive or it will strip, use heat if first pull of plug, Suzuki GLUED , it in. (spec. caulk) The Cat below can be in the way of the left transmision, cross member mount. Photo 5: Next what happens when the clutch cable is never changed out. this is the fire wall cable port. (wrecked) Photo 6: Next, is the clutch pedal damage cause by the same thing. so reweld the shaft, if the saft end is stripped, you need a new pedal assembly, Suzuki still sells them #13. This is a contributors photo, THANKS, and is very clear.! Photo 7: Now the pedal below. see that lever and spline? it won't strip if the cable for $25 and 1hour labor, is replaced. Photo 8: the lever below has 2 index marks, do not fail to see them or add them, before removal. DIY HAHA. use lag bolts not dry wall scews. If you have a welder this is super easy to make, with scrap metal. If you need suzuki part numbers please ask on the BBS.(forum) Not email or PM mail. Please. That way others can find it. or search and find it. Please tell full spec. on car, 1995 Suzuki Sidekick 4wd 2door, 5(speed sure) with 8v or 16valve engine. G16A or B? rev 5 ++++ 4-25-2011 ,, 11-28-11 12-8-2014 added 2 steps, The FSM covers this, I advise reading that first. page 32 plus. |