AboutDavid Scott Expertise Questions regarding the advisability of different kinds of modifications to Samurai/Sidekick/Tracker or various kinds of off-road usage. I will not attempt to do more than provide links for questions about other Suzukis such as Vitara, Grand Vitara, etc. I may or may not give generalized advice for newer models, but have no experience regarding newer models, and will not attempt to give more than the most generalized answers for questions regarding vehicles later than '93 manufacture. I will however, if possible, provide a link that will help you contact a professional in your region.
Experience I've been a professional mechanic for over thirty five years, live in the center of the Rocky Mountains, and have been active in exploring the old mining/4wd roads for decades. I've specific experience with Samurai modification, because that's my personal vehicle.
Education/Credentials Thirty five years of advanced, intensive classes for experienced professionals only. Manufacturer seminars and training classes averaging four to six weeks per year. I'm now a professional heavy duty fleet mechanic, and no longer deal with issues such as MIL (check engine) lights
Expert: David Scott Date: 2/3/2008 Subject: 410 shifting problem
Question Shifting up 1-2-3-4 no problem.
Down shifting from 4 to 3 grinding...4 to 2 no problem.
Any idea about cause and cure.
Answer I'd say the third gear synchro ring is worn.
The trans is small and light, and fairly easy to remove. I've done it myself, by myself easily.
It's one of the easier to disassemble.
You only need the most basic bearing splitters, a small press, or pullers and stuff to disassemble the gear stacks, and a hammer and a couple of long pin punches to re-assemble them
You can get all the bearings, seals, and synchros from either www.hawksuzukiparts.com, or www.rocky-road.com
Hawk is the place for a basic kit, and rocky road is the place for the pricey kit with EVERYTHING.
Oh yeah, get a factory manual.
scotty
