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It begins: 5spd Swap on X90 *pics

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Offline BV1

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It begins: 5spd Swap on X90 *pics
« on: September 05, 2005, 04:14:16 PM »
Well I think I got everything I need, and I am off this week. So I start tommorrow morning, Tuesday on the X90.




I havnt really worked with a transmission before, just engine work mainly. I pretty mechanically adept though, so I will just take it one step at a time.

Heres what I got:




So the question is, where to start. I think I have to drop the plate here shown below:



to get at the tranny itself. As you can the parts transmission has the transfer case bolted onto it already, so I have a spare, yay. I guess instead of seperating them I will just use the transfer case that came on the 5spd instead of taking it off.



I got a clutch for the 5spd, new kit off ebay. But I dont have a flywheel. Didnt come with one! I will go back tommorrow morning and complain. See what I can dig up. How do you but on the new clutch anyways? I got the manual guess I will look it up.



It going to be fun disconnecting all this stuff:



Anyways, wish me luck. If any of you guys have dropped trannys before etc, if you had some advice where to start it would be great!

Thanks again,

-Steve
« Last Edit: September 05, 2005, 04:15:52 PM by BV1 »

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Offline zaggy

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Re: It begins: 5spd Swap on X90 *pics
« Reply #1 on: September 05, 2005, 07:17:45 PM »
Ah come on BV

     I've read enough of your posts to know you've got some mechanical ability. This one is not brian surgery. I've got the same manual and it will walk you through it. Just remember the basics.
- disconnect battery FIRST
- drain it, before starting
- read the manual....take a long hard stare

- Dive in!

We have utmost confidence in you!

Zag
92 Sidekick 4dr, Suzuki Powered Airplane

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Offline BV1

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Re: It begins: 5spd Swap on X90 *pics
« Reply #2 on: September 05, 2005, 07:28:06 PM »
Heheh you make it sound sooo easy.

I just wanted someone to come online and say:

"Oh yah theres a button for that, under the tranny pan, its called swap tranny button, you press it and it all drops out"

Hehe, is that too much to ask?

Oh well, I will take pics along the way.

-Steve

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Offline zaggy

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Re: It begins: 5spd Swap on X90 *pics
« Reply #3 on: September 05, 2005, 07:42:58 PM »
Well come to think of it there is a button like that..........


     Every shop I know has one......

- Swipe Interac card
- Press OK
- Come back 2 days later

Cry when you get the bill!

Seriously it's not that tough...easier than an engine.

Zag
92 Sidekick 4dr, Suzuki Powered Airplane

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Offline BV1

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Re: It begins: 5spd Swap on X90 *pics
« Reply #4 on: September 05, 2005, 08:21:52 PM »
Hehe, I had thought about it... :)

But I WONT DO IT!!! Must resist!

lol

-Steve

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Offline BV1

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Re: It begins: 5spd Swap on X90 *pics
« Reply #5 on: September 05, 2005, 08:25:16 PM »
Hey your from Edmonton, I just brought my X down from there, Im in Winnipeg,

-Steve

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Offline Dihnekis

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Re: It begins: 5spd Swap on X90 *pics
« Reply #6 on: September 05, 2005, 09:19:50 PM »
Let us know how it turns out. I'm looking to do that and a few more things in the upcoming months... 4wd conversion.

What manual do you have?
1988 Suzuki Samurai

31" BFGs, SPOA, 5.14 Calmini Tcase gears, DOM cage, rock sliders, spidertrax wheels

1.6L, header, and 2" flowmaster exhaust coming soon

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Offline ed oorklep

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  • 1992 Suzuki Vitara
    • Suzuki Vitara 4x4
Re: It begins: 5spd Swap on X90 *pics
« Reply #7 on: September 06, 2005, 12:10:53 AM »
Let us know how it turns out. I'm looking to do that and a few more things in the upcoming months... 4wd conversion.

What manual do you have?
4th pic? so that'd mean Haynes  ;)
« Last Edit: September 06, 2005, 07:05:29 AM by ed oorklep »
http://www.suzukivitara4x4.nl
1992 Suzuki Vitara
8cm Body-lift, 33 12.5 R15 General Grabber MT's.
ARB Bull Bar.
3" Suspension lift.

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Offline zaggy

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Re: It begins: 5spd Swap on X90 *pics
« Reply #8 on: September 06, 2005, 06:52:24 AM »
BV1
     If you were out here I coulda got ya the trans dude! I know i would have been cheaper than Team! Next time.

Zag
92 Sidekick 4dr, Suzuki Powered Airplane

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Offline BV1

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Re: It begins: 5spd Swap on X90 *pics
« Reply #9 on: September 06, 2005, 06:54:42 AM »
Doh, oh well, no biggy, thanks for the offer though. Work starts after breakfast :)

-Steve

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Offline BV1

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Re: It begins: 5spd Swap on X90 *pics
« Reply #10 on: September 06, 2005, 09:24:22 PM »
Well after a day of hard labour, I ALMOST got the tranny out.

I would like to introduce whoever said this wanna gonna be easy, to my breaker bar. Which I had to use, repeatedly. I even made custom bent breaker bars to get at the bolts on top of the transmission. Some pics I took got deleted, due to shitty Kodak camera. Just randomly deleting pictures... argh.

I started off by taking out the Driveshafts:



then the interior:



then the LONG parts of taking out the bell housing bolts. They were ALL siezed with lock tight. ALL.... And the top one took an hour by itself.

Then the torque converter to driveshaft bolts. ALl 3 of them, which require turning the crank etc etc....

Then the starter motor.

Then all the connections to the transmission:
  including the cooling lines
  kickdown cable
  Parking cable etc etc...

Then the rear supporting cross bar:



Which I replaced with a jack:



Then I started to lower the transmission slowly, and low and behold it hit the exhaust.

The Exhaust is siezed on, and I CANT free it. I might learn about cutting metal tommorrow.

Yikes I am tired, and its late.

-Steve

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Offline Dihnekis

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Re: It begins: 5spd Swap on X90 *pics
« Reply #11 on: September 06, 2005, 09:41:12 PM »
Is the exhaust usually in the way like that? I just got my exhaust done, and I don't want to have to cut it when I do my conversion... that would suck. Great pictures and write up by the way, I just got my haynes manual today and it looks like quite a job.
1988 Suzuki Samurai

31" BFGs, SPOA, 5.14 Calmini Tcase gears, DOM cage, rock sliders, spidertrax wheels

1.6L, header, and 2" flowmaster exhaust coming soon

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Offline BV1

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Re: It begins: 5spd Swap on X90 *pics
« Reply #12 on: September 07, 2005, 06:51:33 AM »
I dont htink the exhaust would be in the way if you were removing a 5spd. But the edge of the tranny pan catchs the edge of the cat. I tried moving it sideways but its a no go.

I can lift the 5spd tranny the Auto is definetly heavier, very hard to lift.

Continuing today,

-Steve

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Offline zaggy

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Re: It begins: 5spd Swap on X90 *pics
« Reply #13 on: September 07, 2005, 06:56:09 AM »
Paitience Grass Hopper

     Sorry to here everythings been glued on yer X. But keep plugging. On the exhaust, soak it with WD or similar and leave it sit for a bit first. Also you might want to take a break and get a couple of long extensions and universals from the local tool dude. The straighter you can get the torque on the bolts the easier they will come.

Keep sluggin!

BTW I didn't say it was easy, I said it was easier than an engine. LOL

Zag
92 Sidekick 4dr, Suzuki Powered Airplane

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Offline Dihnekis

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Re: It begins: 5spd Swap on X90 *pics
« Reply #14 on: September 07, 2005, 11:23:15 AM »
Ok thanks my exhaust shouldn't be a problem then, I'm swapping my 5 speed with another 5 speed.
1988 Suzuki Samurai

31" BFGs, SPOA, 5.14 Calmini Tcase gears, DOM cage, rock sliders, spidertrax wheels

1.6L, header, and 2" flowmaster exhaust coming soon