tranny years interchange Question

[jtgh]

have 91 kick/tracker. 1.6L 8v sohc
need tranny with or with out transfer case
5sp 4wd, 2dr

what years fit, 89 to 98 ? or ?

thanks for any help.

PS: someone just told me that
"all you need to do is swap out the rear output shaft and it will work with 2wd transmission source car."
I found a 93. seems it will work.

have rebuilt kit so I should be good to go.

[lord_galathon]

From memory I think yours will be a straight swap between 89/95 models, 96 and up have been changed.

I'm not really sure about your output shaft question though.

[jtgh]

THANKS for your help.
It is rumored that a 2wd tranny case is identical to the 4wd and some say change output shaft. ( but I didnt go that route)
I found a junk yard that has an old tranny+xfr case. so I bought it. ( since i need a mid case now)
My xfer case will not comeapart, even with 4000+ pull ! ( used my pickup to pull it apart , unsuccessfull) "Tree, rope,>tranny> Pickup, dump clutch."

Found the tranny output shaft ,(seized ? somehow) to the xfr case input shaft.
this prevents seperation ( all bolts nuts screws removed).

I am taking them both apart and mixing and matching and installing my full rebuild kit I just bought (syncro,bearings,seals).

to pull the siezed tranny apart I have cut a 2 "hole (:eek) in the mid case to begin bashing the coupling point with a huge brass drift I have.

this area of the tranny is the dry mid section (the transition to xfr gear case)

nogo, put penetrating oil on and heated the pinion.
the xfr pinion was rusted solid!
bingo, I have it apart and now I have a good set of gears , for spares to my new junk yard tranny.

first thing I need is the front tranny pinion as some one let the clutch pilot shaft go bad and then ran it till the tip is destroyed.


it is a good feeling to have it all apart.

lesson, put quality marine gp grease on the tail shaft and this will not happen again.

more later...

[jtgh]

have 2 tranny's and a full rebuild kit.
should be done this weekend.

hope my pics help some other tracker/kicker , get-er-done.


progress:

found PO had , put in a 2wd tranny. ( frack me)
to do so, he cut the too long main shaft at the rear end, then he made his own splines with a drimmel tool. (McGyver madness)
However , he did not make them long enough.
That is why the transfer case would not seperate, it was a tapered jam fit ! (into Xfr case front pinion)
one other problem. the place for the rear seal on the main shaft was missing.
this caused all the oil to leak out of main tranny, forever. ( into dry center chamber and out bottom drain hole)

conclusiion:
NO, A 2WD tranny main shaft is INCOMPATIBLE.

bottom cluster gear , installed with new bearings.
assembling , main shaft (correct type) now.

more photos later...

[lord_galathon]

Awesome photos mate. I'd never seen the inside of a gearbox. It's surprising how small the gears are.

[jtgh]

this is my case and
gear sets all clean and new bearing and syncros installed.


bought input shaft from Suzuki for $137 clams (us$). ( this part is high stress due to clutch and PO lousy maintenance)
I'M ready to button it up.

Now we can see why driving with a bad clutch , doubles the repair bill. ( front tranny bearing was distroyed beyond belief)
Very soon it will be triple charges as the part is running out world wide ( new info 6-2007 , quote Suzuki Corp.)

FYI: this tranny must be dissasembled from rear to front. but it is easy to work on.

you need a gear puller ( fork type and clam and a shop press).

the rebuild kit was $150.

If you need gear, buy a spare tranny and swap as new parts are very expensive, unless you need a good input shaft , most are toast in the yards.
findnig a low mileage kick is hard , older than 96.

YMMV , enjoy.