Pulling a Sidekick manual Trans

TheBigSgt · 02-24-2006, 06:07 AM

Well I bought my daughter a tracker a few years ago and on a snowy night, Boom, into and a gaurdrail, insurance totals it. I part it out, make her take the bus for awhile and then I found a 97 sidekick Sport for her. Well, she has always said it makes a funny sound in 4x4. She would bring it to me and I'd drive it around the block and say it seems good to me. Well this time she brings it back and says it's really bad. I drive it and no noise. Then I think to put a load on the drive train. So I go acroos the street to the church parking lot and get the back wheels stuck in the snow. I put it in 4x4 and start to try to move. The most unholy sound comes out from under it. Since I worked for the owner of the local Suzuki dealership before, I go down and have my friend Jim listen to it. Yup, Unholy. We agree that we think it is the transfer case. Remember the tracker, well I had the trans and transfer case sitting down there at the dealership to use if they needed it for a customer. Not alot of space at my place. I stopped by about a month ago and they said it fell over and the trans cracked so the manager throws it away. So I start calling around and a friend had a spare Trans and transfer sitting in his shed. I went to his house and he gave it to me. BIG THANKS BRETT!!! I thanked him very much and off I go. Now this one had been sitting on the ground in the shed for awhile. So I deside to pull the seals and replace them. I call the dealership and order them, yes order them they didn't have them all in stock. So that afternoon I get them, well almost. The one they though they had in stock they didn't, had to wait till the next day to get it. So I get them all and I pull out the old ones. 2 come out with no problem and one doesn't want to leave home. In getting that one out, I bugger up the edge a little and of course didn't notice till it was to late. When I go to install the new seal which is incased in rubber, it gets messed up. OK i start sanding the edges back down. Did I say we are doing this in my friend Bill's garage? So we called the dealship and my friend Cindy says I got the last 2 of those seals in the state and it would take 2-4 days to get it in. Bill runs to the house to start calling the auto parts store. I think he doesn't want it sitting there forever. First he calls PEP BOYS, they don't carry it or show it. Damn his uncle works there. So he calls Auto Zone, hate them, but damn they always have things I need. So I go get it. Now trying to get it in I just couldn't get the new one, not incased in rubber, to go in. OK, I know there is one more seal at Auto Zone, so Bill gives me this Big A$$ socket to use as a press and I hit it with a hammer. In it went. OK we button it all up and we start to put it in. Not hard, 2 guys can handle it VERY easily in my book. So I get it guided in and I'm holding the whole thing up and Bill is putting the crossmember in and some how the whole thing slips and slides out of the block and onto my chest. I caught it as it was coming down so no real pain, so we start over. Glides right back in. THIS TIME I put the 2 lower 17mm nuts on before Bill does the cross member. So bill is buttoning it up, putting things in place and tell him I'm going to put oil in the transfer case from the top since it's alot easier. This is not a bad idea, but you really should have the front drive shaft in BEFORE doing this. So as Bill starts yelling what the %^$#@@!#$ !!! I grap the spare yoke and he puts it in. Now Bill is ready to but the rear drive shaft in and it won't go! Everything else has matched up fine! So we look at it and the spline count is different OK, little problem, we have a spare yoke and it fits! Wait, it's 8:30, we need a Ujoint! Bill says he has a spare for his Sami, but we don't know if it will fit. OK, we call Autozone again and ask him if the Sidekick and Sami U-joint are the same. They are and away we go! So we clean that up. OK bill gets it all done now under it and I get it all done, or so I think, on top and get the interior back together. Bill uses his little pump for putting oil in and we use up all the oil we have but need more. Well it's about 10 pm and we both get up early, so we wait till the next day to finish putting the oil in. So the Next day I pick up a gallon of oil and a different pump, more like a suction thing, suck it up and push it out. Well after messing with this thing and getting oil all over the place I found it easier to unscrew the end of it and pour the oil into it. Then it goes in really good. OK, so it's all done and we take it off the jacks, As Bill lets it down in the back, very quickly, my pop falls off and explodes on the floor. We laugh and drive on. So I start it up, sounds good, I shift into reverse and out the garage we go, feels good, Out in the street I try to put it into First, won't go, I try second, no problem, 3rd, no go, 4th is fine.5th forget it. Now Im saying $%^^%%##%$$$%%#*&^. Back into the garage in second. I call my friend at the dealership and he hasn't a clue. After much debate about doing today or Saturday, we dive into it. No problems taking the trans back out. I pull the shifter off and and everything looked right. Well I have it in my hand and I notice a rubber gromit rolling around in the shifter case. I look at it I see it goes into the the shift hole at the bottem. ALRIGHT I GOT THIS NOW! So we put it all back together and get it all in. So Bill is working on the shafts again and I'm putting in the shifters AGAIN and I can't get the shifter for the trans to seat all the way down. *&*%^$$%#!(*&^!!! So I look at my spare and find you can do these upside down, I never pulled it out all the way so I didn't know this. So I fixed that from the top and everything is working great. I've been driving it all day today and thanks to Bill it took us 3 hours to pull, fix, have a snack, get it in and get home.

Big Thanks to Bill, Brett, Jim, Cindy and Kimmie.

95geo · 02-24-2006, 07:09 AM

i read the whole thing.... im not sure why i did, i meen, i thought there was going to be something informative in it but i kept on reading and reading and reading then i remembered when i was in canada and my ujoint was making noise so i checked it out then came to the conclusion the joint was dry and the bearings were trashed so i called rockford driveline and had them overnight 2 of them for the lovely price of $120, they didnt make it to canada before i left but the good thing is a friend of mine went there the next weekend and picked them up for me and i finished the weekend on a kobbled together rockford/1310 ujoint with about .015 between the trunion and the needle bearings. then i kept reading and reading and i finally realized that my little story i just remembered had more tech in it that your adventures.

jp008 · 02-24-2006, 08:39 AM

Thanks Sarge.

TheBigSgt · 02-24-2006, 09:59 AM

Quote:

Originally Posted by 95geo

i read the whole thing.... im not sure why i did, i meen, i thought there was going to be something informative in it but i kept on reading and reading and reading then i remembered when i was in canada and my ujoint was making noise so i checked it out then came to the conclusion the joint was dry and the bearings were trashed so i called rockford driveline and had them overnight 2 of them for the lovely price of $120, they didnt make it to canada before i left but the good thing is a friend of mine went there the next weekend and picked them up for me and i finished the weekend on a kobbled together rockford/1310 ujoint with about .015 between the trunion and the needle bearings. then i kept reading and reading and i finally realized that my little story i just remembered had more tech in it that your adventures.

Maybe it said.

PEP BOYS doesn't have the parts.
Auto Zone may.
Put the 17mm on.
Make sure the shifter is in right.
While the transfers look the same, they can be different.
It can be done quickly.
Put the oil in after the front drive shaft!

95geo · 02-24-2006, 10:24 AM

Quote:

Originally Posted by TheBigSgt

Maybe it said.

PEP BOYS doesn't have the parts.
Auto Zone may.
Put the 17mm on.
Make sure the shifter is in right.
While the transfers look the same, they can be different.
It can be done quickly.
Put the oil in after the front drive shaft!

thats better, cliffs notes

TheBigSgt · 02-24-2006, 11:46 AM

Quote:

Originally Posted by 95geo

thats better, cliffs notes

Some people REALLY need then!
The Chilton manual says you can pull a transfer without pulling a Trans! Good frackin luck there!

TatorZuk · 02-24-2006, 06:00 PM

Didn't know the "Big Sarge" was a Zuk guy...cool.

TheBigSgt · 02-24-2006, 07:29 PM

Quote:

Originally Posted by TatorZuk

Didn't know the "Big Sarge" was a Zuk guy...cool.

I have a 96 that I bought brand new in August of 96 for my wifes B-day and it now has 56k on it. I also have the 97 I bought 2 years ago for my daughter. I'd really like to find a X-90 for a daily driver!

02-24-2006, 06:07 AM	#1
TheBigSgt Wheeler Join Date: Jun 2001 Member # 5087 Location: Roy Ut Posts: 300	Pulling a Sidekick manual Trans Well I bought my daughter a tracker a few years ago and on a snowy night, Boom, into and a gaurdrail, insurance totals it. I part it out, make her take the bus for awhile and then I found a 97 sidekick Sport for her. Well, she has always said it makes a funny sound in 4x4. She would bring it to me and I'd drive it around the block and say it seems good to me. Well this time she brings it back and says it's really bad. I drive it and no noise. Then I think to put a load on the drive train. So I go acroos the street to the church parking lot and get the back wheels stuck in the snow. I put it in 4x4 and start to try to move. The most unholy sound comes out from under it. Since I worked for the owner of the local Suzuki dealership before, I go down and have my friend Jim listen to it. Yup, Unholy. We agree that we think it is the transfer case. Remember the tracker, well I had the trans and transfer case sitting down there at the dealership to use if they needed it for a customer. Not alot of space at my place. I stopped by about a month ago and they said it fell over and the trans cracked so the manager throws it away. So I start calling around and a friend had a spare Trans and transfer sitting in his shed. I went to his house and he gave it to me. BIG THANKS BRETT!!! I thanked him very much and off I go. Now this one had been sitting on the ground in the shed for awhile. So I deside to pull the seals and replace them. I call the dealership and order them, yes order them they didn't have them all in stock. So that afternoon I get them, well almost. The one they though they had in stock they didn't, had to wait till the next day to get it. So I get them all and I pull out the old ones. 2 come out with no problem and one doesn't want to leave home. In getting that one out, I bugger up the edge a little and of course didn't notice till it was to late. When I go to install the new seal which is incased in rubber, it gets messed up. OK i start sanding the edges back down. Did I say we are doing this in my friend Bill's garage? So we called the dealship and my friend Cindy says I got the last 2 of those seals in the state and it would take 2-4 days to get it in. Bill runs to the house to start calling the auto parts store. I think he doesn't want it sitting there forever. First he calls PEP BOYS, they don't carry it or show it. Damn his uncle works there. So he calls Auto Zone, hate them, but damn they always have things I need. So I go get it. Now trying to get it in I just couldn't get the new one, not incased in rubber, to go in. OK, I know there is one more seal at Auto Zone, so Bill gives me this Big A$$ socket to use as a press and I hit it with a hammer. In it went. OK we button it all up and we start to put it in. Not hard, 2 guys can handle it VERY easily in my book. So I get it guided in and I'm holding the whole thing up and Bill is putting the crossmember in and some how the whole thing slips and slides out of the block and onto my chest. I caught it as it was coming down so no real pain, so we start over. Glides right back in. THIS TIME I put the 2 lower 17mm nuts on before Bill does the cross member. So bill is buttoning it up, putting things in place and tell him I'm going to put oil in the transfer case from the top since it's alot easier. This is not a bad idea, but you really should have the front drive shaft in BEFORE doing this. So as Bill starts yelling what the %^$#@@!#$ !!! I grap the spare yoke and he puts it in. Now Bill is ready to but the rear drive shaft in and it won't go! Everything else has matched up fine! So we look at it and the spline count is different OK, little problem, we have a spare yoke and it fits! Wait, it's 8:30, we need a Ujoint! Bill says he has a spare for his Sami, but we don't know if it will fit. OK, we call Autozone again and ask him if the Sidekick and Sami U-joint are the same. They are and away we go! So we clean that up. OK bill gets it all done now under it and I get it all done, or so I think, on top and get the interior back together. Bill uses his little pump for putting oil in and we use up all the oil we have but need more. Well it's about 10 pm and we both get up early, so we wait till the next day to finish putting the oil in. So the Next day I pick up a gallon of oil and a different pump, more like a suction thing, suck it up and push it out. Well after messing with this thing and getting oil all over the place I found it easier to unscrew the end of it and pour the oil into it. Then it goes in really good. OK, so it's all done and we take it off the jacks, As Bill lets it down in the back, very quickly, my pop falls off and explodes on the floor. We laugh and drive on. So I start it up, sounds good, I shift into reverse and out the garage we go, feels good, Out in the street I try to put it into First, won't go, I try second, no problem, 3rd, no go, 4th is fine.5th forget it. Now Im saying $%^^%%##%$$$%%#&^. Back into the garage in second. I call my friend at the dealership and he hasn't a clue. After much debate about doing today or Saturday, we dive into it. No problems taking the trans back out. I pull the shifter off and and everything looked right. Well I have it in my hand and I notice a rubber gromit rolling around in the shifter case. I look at it I see it goes into the the shift hole at the bottem. ALRIGHT I GOT THIS NOW! So we put it all back together and get it all in. So Bill is working on the shafts again and I'm putting in the shifters AGAIN and I can't get the shifter for the trans to seat all the way down. &%^$$%#!(&^!!! So I look at my spare and find you can do these upside down, I never pulled it out all the way so I didn't know this. So I fixed that from the top and everything is working great. I've been driving it all day today and thanks to Bill it took us 3 hours to pull, fix, have a snack, get it in and get home. Big Thanks to Bill, Brett, Jim, Cindy and Kimmie. Last edited by TheBigSgt; 02-24-2006 at 06:26 AM.

02-24-2006, 08:39 AM	#3
jp008 Registered User Join Date: Dec 2001 Member # 8690 Location: Layton UT Posts: 779	Thanks Sarge. __________________ Jim Phillips (D.O.R.) 87 Samurai-91 Kick

02-24-2006, 06:00 PM	#7
TatorZuk Granite Guru Join Date: Jan 2003 Member # 16608 Location: Dakota Territory Posts: 888	Didn't know the "Big Sarge" was a Zuk guy...cool. __________________ '88 Zuk

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02-24-2006, 07:09 AM	#2
95geo Registered User Join Date: Dec 2002 Member # 15461 Location: dryden,michigan Posts: 2,392	i read the whole thing.... im not sure why i did, i meen, i thought there was going to be something informative in it but i kept on reading and reading and reading then i remembered when i was in canada and my ujoint was making noise so i checked it out then came to the conclusion the joint was dry and the bearings were trashed so i called rockford driveline and had them overnight 2 of them for the lovely price of $120, they didnt make it to canada before i left but the good thing is a friend of mine went there the next weekend and picked them up for me and i finished the weekend on a kobbled together rockford/1310 ujoint with about .015 between the trunion and the needle bearings. then i kept reading and reading and i finally realized that my little story i just remembered had more tech in it that your adventures.