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ZUKIWORLD Discussion Forum => Technical Discussion - Beginner / Repair => Topic started by: JNM78 on October 07, 2010, 01:38:23 PM

Title: 5sp getting in gear problems!!
Post by: JNM78 on October 07, 2010, 01:38:23 PM

  I have a 95 kick w/a 5speed, have new clutch/preasure plate, and cable.  The problem is that it wont go into 1st or 2nd, and grinds into rev. unless I put the transfer case into neutral, then it will go into all of the gears fine.
 So when i,m on the trails or muddin I put the xfrcase in -n- and then sel 1st or 2nd and then 4L and off i go. Can someone help me.

 I would like to rebuild the tranny.  can anyone let me know where to buy a kit, and are there any special tools needed?

Title: Re: 5sp getting in gear problems!!
Post by: fordem on October 07, 2010, 02:56:17 PM

Sounds like your clutch is not disengaging completely.

Title: Re: 5sp getting in gear problems!!
Post by: gearjam on October 07, 2010, 06:07:03 PM

I agree with above

Title: Re: 5sp getting in gear problems!!
Post by: Zukipilot on October 08, 2010, 04:00:55 PM

Check your clutch cable. The casings will break down over time and allow the cable to kink or bend causing this problem.

Zig

Title: Re: 5sp getting in gear problems!!
Post by: JNM78 on October 10, 2010, 03:18:38 AM

 I found the problem, Had mud packed in the bell housing. I had to put it up on jacks and use the hose and air gun to blow out the mud. working fine now.
 I did notice that the plastic cup under the shifter ball is missing, Does anyone know where i can find these parts?

Title: Re: 5sp getting in gear problems!!
Post by: Skyhiranger on October 13, 2010, 08:51:26 AM

Quote from: JNM78 on October 10, 2010, 03:18:38 AM

 I did notice that the plastic cup under the shifter ball is missing, Does anyone know where i can find these parts?

Junkyard, wanted ads, dealer.
Oh, wait, are you talking about the "ball" that is the pivot point of the tranny shifter?  If so, there isn't a cup that goes under it...there is just one on the top side of the ball.

Title: Re: 5sp getting in gear problems!!
Post by: Drone637 on October 13, 2010, 11:58:50 AM

Hawk Suzuki is a great place to call if your missing random parts.

As for the bell housing being full of mud, do you have the metal cover plate that goes just under the oil pan and in front of the flywheel?

Title: Re: 5sp getting in gear problems!!
Post by: JNM78 on October 22, 2010, 04:20:14 AM

 No, theirs not one there, I thought the 5sp. did not have a dust shield, I can make one, I'm looking for metal/alum. to make skid plates now to try and help this problem. 

Title: Re: 5sp getting in gear problems!!
Post by: Drone637 on October 22, 2010, 04:53:06 PM

I believe they all have a dust shield.  I know my 4 speed and the trackers do.  Not sure about a Sammy though, as I don't have that particular model.

If not I would put something on there. 

Title: Re: 5sp getting in gear problems!!
Post by: Skyhiranger on October 22, 2010, 06:05:29 PM

samurais have dust shields.

Title: Re: 5sp getting in gear problems!!
Post by: joesteak on October 30, 2010, 04:49:59 PM

Quote from: JNM78 on October 10, 2010, 03:18:38 AM

I found the problem, Had mud packed in the bell housing. I had to put it up on jacks and use the hose and air gun to blow out the mud. working fine now.

The mud is a killer.  I had the same problem with mine not wanting to go into 1st gear and it was because my throw-out bearing was shot from mud getting in there.