more nfo:
the center section is dry.
this section rear (xfr input pinion) as a spline shaft.
so keep in mind that you can cut a 1/4" hole in this case section CL of drive shaft and then spray in WD40 or what-not , on to spline.
The only thing holding it is the hidden bolt and the spline juncture !!]
need more photo or help , let me know.
dont forget to pull 4wd shifter top too.
the 5sp shifter sits on an aluminum ARM.
this arm is bolted directly to the top of the 5sp
remove it (periferial bolts)
then look on top of center dry case at its juncture the 5sp, bingo a hidden bolt. same as the others.
darn i forgot one.
the reverse idler gear shaft lock bolt.
on the right side of 5sp is a bolt all by its self.
removeing it allows the reverse shaft to float.
this give more allowed movement of the main shaft.
just put it back after done removing xfr case!!!
this is the infamous bolt jelly lube joints remove thinking its a drain bolt. bad news. with that.
two photos
showg what connects.
1-rear cluster bearing can spin and sieze ?
2- main shaft spline can be rusted on end?
you mUST pull all shifters and shift towers ! or the H forks will lock you up.
you must pull rev. idler bolt. ( so it says)
suzuki does not put grease on the spline at the factory
and if you go under water, water can reach this point.
not good. ( center case has bottom breather hole)
I bead blasted mine and put marine wp grease on mine.
I have tons of photos for my tranny. also a spare one in parts.
the fsm does explain how to pull a xfr with out pulling tranny. step by step.
Error: the manual i gave you, does not tell you how to remove xfr case, only how to repair it.
sorry.
the main veh. FSM shows that. which i do not have with me at the moment.
I will tell you how I seperated my Impossible xfr. ( good story)
1- tied 5-sp tranny to tree, then tied xfr to hitch of huge truck.
then pulled, no joy! maybe 8000 lbs force there.
I then got a spare tranny xfer .
I then took origional tranny and cut a 2x2 inch hole in the side of the dry case section with a sawsALL. I then took a 1 inch brass drift and placed it against the XFR input shaft and hit it with a 5 lbs sludge.
with wd40 and on the 5th hit, it seperated.
My shaft had home made splines made from a drimmel tool.
it was a wedge fit,
in your case the rear cluster gear bearing my be spun and siezed?
or you have rust.
block of wood behind dizzy and firewall. (says remove dizzy)
rem, console
rem, prop shafts
rem, cat ctr pipe
discon, speedo cable
jack under xfrcase
rem cross member
rem 5 bolts of gear shift lever case on 5 speed trans
rem hidden bolt under same.
rem 4wd switch couplers
rem all transfer case bolts
slide xfr case to rear , lowering jack as necessary , keep eye on dizzy.
that is every step, out of book. (condensed)
enjoy
I seriously owe you a keg of ur choice, thank you so much.
It was that bolt ontop, and after it came out, everything else went VERY smoothly (allbiet rushed)... I removed that bolt, took the old case off, put the new one on, and put everything except the center console backtogether in 2 and a half hours. Couldnt have done it without you, and I wouldnt have a vehicle for this weekend. Now, thanks to you, I've got a working 4x4 tracker. Again, I cant tell you enough how much I apprecate your help
If you're ever going to be in Wisconsin, particularly Eau Claire, Feel free to shoot me a PM.
~Nate
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Transfer case replacement kicking my ***
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