ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum

ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: big_kountry21 on February 07, 2008, 10:37:30 AM

Title: 90 to a 96?????????????????help
Post by: big_kountry21 on February 07, 2008, 10:37:30 AM
will the tranny interchange between a 90 and a 96? help please
Title: Re: 90 to a 96?????????????????help
Post by: Armour on February 07, 2008, 01:27:23 PM
man or auto?
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 07, 2008, 02:23:35 PM
5 speed manual
Title: Re: 90 to a 96?????????????????help
Post by: Armour on February 07, 2008, 05:00:33 PM
i think they are all the same. I am not sure if they differ from 8V to 16V though!
Title: Re: 90 to a 96?????????????????help
Post by: takai on February 07, 2008, 05:26:29 PM
I would think that they interchange. I believe the bottom end is the same for both the 8V and the 16V and that would be what the belhousing bolts up to.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 07, 2008, 05:33:37 PM
i called the chevy dealership and he said differ part numbers.
Title: Re: 90 to a 96?????????????????help
Post by: Armour on February 07, 2008, 09:38:54 PM
Thats prob the difference. 90 had 8V and 96 was  a 16V i am almost certain. Can anyone else back this up? I am not 100%.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 07, 2008, 09:40:36 PM
so does that mean they will match up?
Title: Re: 90 to a 96?????????????????help
Post by: Armour on February 07, 2008, 09:42:55 PM
I thought they were the same. But don't quote me. If I were you i would hold tight for a bit and see what some more people have to say on this post.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 07, 2008, 09:45:06 PM
kk....... i hate to buy that tracker and the shit not bolt up...... its only $300 though
Title: Re: 90 to a 96?????????????????help
Post by: Skyhiranger on February 08, 2008, 05:00:39 PM
16V and 8V manual trannies will interchange.  The 16V engines have bracing brackets that go back to tranny.....but an 8V tranny will work (just don't use the bracing brackets).
The 16V tranny has a .795 5th gear ratio.
The 8V tranny has a .86 5th gear ratio.
All other gear ratios are the same.
The 90 tranny may have 2 sensors on the tranny (the 5th gear sensor and the reverse sensor).....the 96 tranny will probably just have the reverse sensor.  Just don't worry about hooking up the 5th gear sensor on the 90 tranny....it will still work fine without it hooked up.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 08, 2008, 05:07:14 PM
you are the freakin man. i needed to know that. i found a 90 trak for 300 bucks and the tranny for mine is 450 at the cheapest...... thanks a million.
Title: Re: 90 to a 96?????????????????help
Post by: Skyhiranger on February 08, 2008, 05:44:05 PM
One other thing to note.....the tcase on the 90 tranny will have a 26 spline (IIRC) output shaft......the tcase on your 96 will have a 16 spline (IIRC) output shaft.  The tcases will interchange, so you won't have a problem there, or you can swap the slip yoke from the 90s driveshaft over to the 96s driveshaft.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 08, 2008, 06:06:37 PM
which is better 16 or 26?
Title: Re: 90 to a 96?????????????????help
Post by: Skyhiranger on February 08, 2008, 06:15:05 PM
which is better 16 or 26?

IMO, there is no difference.  I don't know why they changed the spline count.
Title: Re: 90 to a 96?????????????????help
Post by: lil_Truck on February 11, 2008, 08:22:34 AM
I've done this swap.  I just changed the bell housing on the trany so that I could use all my suport brackets.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 11, 2008, 09:17:51 AM
sweet thanks..... i found a 90 2 door trak as the donor......
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 13, 2008, 09:39:15 AM
i need an opinion. the 90 trak i found has auto hubs. i have manual... which is better?
Title: Re: 90 to a 96?????????????????help
Post by: lil_Truck on February 13, 2008, 10:31:35 AM
Stick with the manual!

Auto's are too unpredictuable off road.  Good for a DD.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 13, 2008, 10:34:35 AM
i need dependability
Title: Re: 90 to a 96?????????????????help
Post by: idaholwb on February 13, 2008, 04:54:07 PM
 The transfercase rear output didn't change until 99 when they changed platforms. The webbing on the case is different and the rear output is the larger shaft with fewer splines. If you found one older than that with the coarse splines it just means that someone swapped for whatever stupid reason. The transmissions are identical except for the 5th gear switch that the early 8V 1.6s used for the EGR valve.
 Even the transmission from a 1.8 will bolt up, same bellhousing pattern, not sure about the depth of the bell though because the 1.8 might have a thicker flywheel like the 2.0 did.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 13, 2008, 05:09:19 PM
thanks .... i'm going from a 1.6 16v to a 1.6 8v 96 to a 90
Title: Re: 90 to a 96?????????????????help
Post by: Skyhiranger on February 13, 2008, 06:47:30 PM
The transfercase rear output didn't change until 99 when they changed platforms. The webbing on the case is different and the rear output is the larger shaft with fewer splines. If you found one older than that with the coarse splines it just means that someone swapped for whatever stupid reason. The transmissions are identical except for the 5th gear switch that the early 8V 1.6s used for the EGR valve.
 Even the transmission from a 1.8 will bolt up, same bellhousing pattern, not sure about the depth of the bell though because the 1.8 might have a thicker flywheel like the 2.0 did.

The tcase output shaft changed in 96....I have talked to several people at zuwharrie that can validate it......unless in all the 96 and up tcases they are finding someone has swapped output shafts.
Early trannys had both a 5th gear/EGR switch and a backup light/reverse switch.....the later trannys done away with the 5th gear/EGR switch and just have the backup light/reverse switch.
Title: Re: 90 to a 96?????????????????help
Post by: lil_Truck on February 14, 2008, 08:41:56 AM
I've found with Trackers, the shaft change seemed to come with the 16V motors.  1995.5 and up.
Title: Re: 90 to a 96?????????????????help
Post by: Skyhiranger on February 14, 2008, 12:01:40 PM
I've found with Trackers, the shaft change seemed to come with the 16V motors.  1995.5 and up.

Well yeah.  Since starting with the 96 model year, 16Vs were the only motor choice. ;)
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 14, 2008, 06:36:14 PM
so what would i have to swap out to do the 90 tranny in the 96.
Title: Re: 90 to a 96?????????????????help
Post by: lil_Truck on February 15, 2008, 05:46:45 AM
I switched the bell housing so that I could hook up all the brackets.  Thats all I changed on the trany.

I don't know what shape your clutch is in, but this is a good time to think about it.  At least maby a new throw out bearing.  I've ran a lot of mud and the bearing felt like it was grinding so I replaced it eventhough it wasn't that old.

My driveshafts are the 16 spline and I have a 4.25 gearing in it.  So I stay'ed with my original case.

The only problem I had was the fact that I was using different cases.  When I bulled my case the aligning pins stayed in the case.  When I pulled the other case the pins stayed in the trany.  So when I put them together I couldn't get the gap to close.  So make sure your pins are one way or the other.  Good luck.
Title: Re: 90 to a 96?????????????????help
Post by: big_kountry21 on February 15, 2008, 01:23:09 PM
thanks... i got it today. i'll keep ya'll posted.
Title: Re: 90 to a 96?????????????????help
Post by: Skyhiranger on February 20, 2008, 08:02:06 AM
The only problem I had was the fact that I was using different cases.  When I bulled my case the aligning pins stayed in the case.  When I pulled the other case the pins stayed in the trany.  So when I put them together I couldn't get the gap to close.  So make sure your pins are one way or the other.  Good luck.

The "pins" are removeable.  Sometimes they are hard to get out without damaging them, but they will come out.