ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: BV1 on September 05, 2005, 04:14:16 PM
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Well I think I got everything I need, and I am off this week. So I start tommorrow morning, Tuesday on the X90.
(http://www.members.shaw.ca/diatech/X90/x90.jpg)
(http://www.members.shaw.ca/diatech/X90/x90-4.jpg)
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:
(http://www.members.shaw.ca/diatech/X90/5spdparts.JPG)
(http://www.members.shaw.ca/diatech/X90/5spdtrqanny2.JPG)
So the question is, where to start. I think I have to drop the plate here shown below:
(http://www.members.shaw.ca/diatech/X90/x90under.JPG)
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.
(http://www.members.shaw.ca/diatech/X90/5spdtranny.JPG)
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.
(http://www.members.shaw.ca/diatech/X90/Clutch.JPG)
It going to be fun disconnecting all this stuff:
(http://www.members.shaw.ca/diatech/X90/autotranny.JPG)
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
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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
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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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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
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Hehe, I had thought about it... :)
But I WONT DO IT!!! Must resist!
lol
-Steve
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Hey your from Edmonton, I just brought my X down from there, Im in Winnipeg,
-Steve
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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?
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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 ;)
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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
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Doh, oh well, no biggy, thanks for the offer though. Work starts after breakfast :)
-Steve
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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:
(http://www.members.shaw.ca/diatech/X90/Driveshafts.JPG)
then the interior:
(http://www.members.shaw.ca/diatech/X90/intapart.JPG)
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:
(http://www.members.shaw.ca/diatech/X90/crossbar.JPG)
Which I replaced with a jack:
(http://www.members.shaw.ca/diatech/X90/jack.JPG)
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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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.
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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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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
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Ok thanks my exhaust shouldn't be a problem then, I'm swapping my 5 speed with another 5 speed.
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I presume you are only disconection it at the manifold? and the crossmember and then you can push it to the side and tie it down with some zipties should have noproblemb after that.
Oh and I have a question from when I swaped the motor in my 89 kik, the motor I rebuild came out of a 92 or a 94, and had a bracket on each side of the bottom that attached to the bell housing, now the tranny in my 89 did not only not have bolt holes for the brackets, but they did not event touch the bell housing. and were not on the motor i took out, the motor bolted up and runs great, but did chevy do somthing to the bell housing in the tracker for more support?
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My X90 has those bell housing supports on it, and YES they are in the way you have to take BOTH sides of the passenger side support off, to remove it, and it has to be removed to take out the transmission.
Anyways, I got the tranny out, got lots of pics. I was at a golf tournament today, so no time to post pics or further the work. But I got the clutch installed, the flywheel, and shes all ready to bolt in tommorrow.
The Auto transmission, is 2-3 inches longer then the 5spd, and the speedo gearing, in the transfer case, both are the same. 19 teeth. Differences must me in the speedo itself for the 4.62 and 5.12 gearing.
Pics tommorrow,
-Steve
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You didn't have to seperate the transmission from the transfer case did you? I've found a parts tracker at a U Pull it yard and I'm going to get it saturday... hope it doesn't take too long. Oh and the front axle too.
Out of curiousity, what are the years that are interchangable? I have a 94 tracker, I was pretty sure I could use the tranny out of anything 89-95. Can I use more years than that? Also, I have an 8v, do I have to get the tranny off an 8v for some reason? Oh and if its a 4door can I still take the transmission and transfer from it even if I have a 2door?
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Hehe, you asking the wrong guy, zaggy would know. I didnt have to seperate that transfer case though to get the auto out. Althought, the manual says you do, on the 5spd, but not on the auto. Wierd, I doubt it, I will let you know later today.
Pretty sure that housing is the same on all the 1.6L motors.
-Steve
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Hey, I need a shot of a 5spd engine bay so I can see how the clutch cable is routed.
Thanks!
-Steve
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I found this:
(http://www.izook.com/tech/samurai/engine/clutchcable/images/diagram2.jpg)
Where is the cable bracket though?
-Steve
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steve that pic is of a sami tho right?
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Yeah, I think I found out where it connects. But I am missing the actual bracket :(
-Steve
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Ok some pics didnt turn out, but I got most of them. So I got the old transmission out finally.
(http://www.members.shaw.ca/diatech/X90/waste.JPG)
I had to move the exhaust to the side as I was saying:
(http://www.members.shaw.ca/diatech/X90/moveexh.JPG)
Tons of cables connected to it the auto, some of them I disconnected properly, some I cut. I leave you to decide what you want to do. I was getting near the end of my rope at the part of the project. But it DID come out! Heres a pic of the driveplate and those cables for the Auto, the driveplate and its two counterparts become scrap:
(http://www.members.shaw.ca/diatech/X90/cables.JPG)
(http://www.members.shaw.ca/diatech/X90/driveplate.JPG)
There was a length difference in the two trannys. This means new drive shafts! 3inches shorter the 5spd is, as yoda would say.
(http://www.members.shaw.ca/diatech/X90/2trans.JPG)
This becomes a greater pain in the ass later as pics will show. I went to change the speedo gears:
(http://www.members.shaw.ca/diatech/X90/speedo1.JPG)
(http://www.members.shaw.ca/diatech/X90/nodiffspeedo.JPG)
BUT they are not any different! Both 19 teeth!.... ok.... maybe the ecu.... w/e....
So I got the 5spd all ready to install, changed the release bearings and all that jazz. This is really straight forward, you will figure it out, my pics of this didnt turn out. Just take all the parts that come with the exedy kit off ebay, and install them! :) One bearing into the flywheel and one bearing into the transmission.
(http://www.members.shaw.ca/diatech/X90/prepped.JPG)
Then install the clutch onto the crank, replacing the auto driveplate, using the alignment too and all that stuff....
(http://www.members.shaw.ca/diatech/X90/clutch%20install.JPG)
OHOH... and the starter motor IS the same! YES!
So now lets get the 5spd up and installed:
(http://www.members.shaw.ca/diatech/X90/start5.JPG)
(http://www.members.shaw.ca/diatech/X90/start5whole.JPG)
I did finally get it all in and installed, using two jacks and then finally, removing the front red jack and holding the 5spd in my hands, lieing on my back and just toying with it until it slid in. The rear was still supported.
Now remember I said it was a PITA because the new transmission is shorter... IT IS:
(http://www.members.shaw.ca/diatech/X90/Holeinint.JPG)
(http://www.members.shaw.ca/diatech/X90/bodydiff.JPG)
The 5spd hits the body. Nothing a small shave doesnt fix. Didnt take much actually.. and oh, flip the rubber around on your AUTO 4-Wheel transfer case boot, otherwise it wont go into 4-lo.
(http://www.members.shaw.ca/diatech/X90/fliptransfer.JPG)
As for the consoles, lo and behold X90 and SIDEKICK consoles are the same! 5 spd sidekick goes right in. (I want a BLACK ONE THOUGH, someone help me out here, needs the parts!)
(http://www.members.shaw.ca/diatech/X90/consoles.JPG)
The AUTO ECU has an extra plug and is blue:
(http://www.members.shaw.ca/diatech/X90/ecus.JPG)
(http://www.members.shaw.ca/diatech/X90/ecus2.JPG)
Got the car running on the AUTO with a CEL wouldnt run on the 5spd.... Maybe a bad ECU.
So yeah, got it running, shifted through a few gears on the block, without the clutch, and it works.
NOW... changing the pedals tommorrow, AND... CLUTCH bracket.
...........
Please! Does someone have a pic of a stock 5spd clutch cable and bracket?? I have the cable, but I need to know how its run, and where the bracket connects at the tranny. Nothing intact at the wrecker and the manual is useless.... If your reading this, and you have a 5spd sidekick/tracker/X90... Can you take a pic of underneath your car of the clutch cable bracket, where it bolts on, and how the cable is run? Please...
...........
Thanks guys,
-Steve
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Ok, all done, finished and working right.
Theres a couple things one should know here.
1) First off, your backup lights are on the BIG Auto connector on the bottom, left over after you take out the AUTO tranny. You connect two pins and the lights light up, you have to splice into those wires and hook them up to thw white switch on top the MT.
You can find out the two pins by me taking a pic, or by take your auto and shifting it into reverse (when its out) and checking for continuity across two pins on the male side of the connector (on the tranny).
2) The white switch on top of the Transfer case is for the 4WD light.
3) Make sure you have a good UNRUSTED clutch cable, your will regret it.
4) BECAREFUL when changing the pedals, you MUST remove the brake booster, this is really easy, just pull it out and leave the lines connected to back it off a bit. BUT YOU MUST DO THIS, or it will break (doh).
5) It WILL run and work with good mileage on the AUTO ECU but you wanna get a 5spd ECU ASAP.
6) Change the fluid on the front and rear diff and the TC and the MT. DOnt go TOO thick. Good time to switch to synthetic.
I will keep you posted more later,
-Steve
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Xlnt job Steve........
Told ya you could do it!
now you've got a cool rig to beat winter with.
zag