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Underbody braces, turbos and more!

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PostPosted: Sat Aug 12, 2006 8:53 am 
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This is the entire manual transmission section from the Suzuki SA310 factory service manual. This information will cover transmission servicing for manual transmission MK1 vehicles (Suzuki SA310, Forsa, Sprint & Firefly). Now updated to include details about the 4 pinion differential featured on turbocharged models.


7A-1 Transaxle Contents, General Description
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7A-2 Transaxle Cross-section
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7A-3 Transaxle Exploded View
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7A-4 Gear Shifting Mechanism
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7A-5 5th & Reverse Shift Cam
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7A-6 Diagnosis
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7A-7 On Car Service - Checking Oil Level
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7A-8 Gear Shift Control Components
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7A-9 Gear Shift Control Lever Adjustment
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7A-10 Tightening Torque and Lubrication Points
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7A-11 Fifth Gears
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7A-12 Fifth Gears con't
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7A-13 Fifth Gears con't
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7A-14 Fifth Gears con't
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7A-15 Fifth Gears con't
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7A-16 Gear Shift and Select Shaft Assembly
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7A-17 Gear Shift and Select Shaft Assembly con't
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7A-18 Gear Shift and Select Shaft Assembly con't
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7A-19 Gear Shift and Select Shaft Assembly con't
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7A-20 Transaxle Assembly
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7A-21 Transaxle Assembly con't
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7A-22 Unit Repair Overhaul - Disassembly of Transaxle
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7A-23 Unit Repair Overhaul - Disassembly of Transaxle con't
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7A-24 Unit Repair Overhaul - Transaxle Right Case - Right Bearing Cups and Input Shaft Oil Seal
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7A-25 Unit Repair Overhaul - Transaxle Right Case - Reverse Gear Shift Lever, Differential Side Oil Seal, Gear Shift Shaft
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7A-26 Unit Repair Overhaul - Transaxle Right Case - Gear Shift Shaft con't
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7A-27 Unit Repair Overhaul - Transaxle Left Case - Gear Shift Forks and Shift Shafts
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7A-28 Unit Repair Overhaul - Transaxle Left Case - Input Shaft Assembly
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7A-29 Unit Repair Overhaul - Transaxle Left Case - Countershaft Assembly
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7A-30 Unit Repair Overhaul - Transaxle Left Case - Countershaft Assembly con't
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7A-31 Unit Repair Overhaul - Transaxle Left Case - Countershaft Assembly con't
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7A-32 Unit Repair Overhaul - Transaxle Left Case - Countershaft Assembly con't
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7A-33 Unit Repair Overhaul - Transaxle Left Case - Differential Assembly
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7A-34 Unit Repair Overhaul - Transaxle Left Case - Differential Assembly con't
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7A-35 Unit Repair Overhaul - Reassembly of Transaxle
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7A-36 Unit Repair Overhaul - Reassembly of Transaxle con't
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7A-37 Unit Repair Overhaul - Reassembly of Transaxle con't
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7A-38 Unit Repair Overhaul - Reassembly of Transaxle con't
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7A-39 Unit Repair Overhaul - Reassembly of Transaxle con't
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7A-40 Unit Repair Overhaul - Required Service Materials
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7A-41 Special Tools
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7A-42 Special Tools con't
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<hr>


EPI Turbo supplement
This contains info on the 4 pinion differential unique to MK1 turbos:

Section 7A Transaxle (Contents, General Description)
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7A-2 Differential Exploded View
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7A-3 Unit Repair (Disassembly)
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7A-4 Unit Repair (Disassembly con't, Assembly)
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7A-5 Unit Repair (Assembly con't)
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7A-6 Unit Repair (Assembly con't, Reassembly of Transaxle)
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EDIT: updated to include turbo tranny info

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jaguar,vettes&sprints wrote:
...can you inlighten me about lihtan's
( miracle pour hole)
maybe a picture Thanks


Last edited by Lihtan on Sat Aug 26, 2006 2:51 pm, edited 2 times in total.

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PostPosted: Sun Aug 13, 2006 4:03 pm 
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Did the Mark 1 GTI have the same four pinion diff, that the Turbo has?
...I know my 1989 GTI (Mark 2) does not. Darcy


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PostPosted: Sat Aug 26, 2006 2:52 pm 
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Updated to include turbo supplement data about the 4 pinion diffs.

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jaguar,vettes&sprints wrote:
...can you inlighten me about lihtan's
( miracle pour hole)
maybe a picture Thanks


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PostPosted: Fri Sep 08, 2006 8:11 am 
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thanks for the info!!


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PostPosted: Thu Sep 14, 2006 10:22 am 
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Hey lithan, would you happen to know if the internals from and MK1 box would fit into an mk2 case?

Thanks

Ryan


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PostPosted: Fri Sep 15, 2006 7:06 pm 
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FiveZigen wrote:
Hey lithan, would you happen to know if the internals from and MK1 box would fit into an mk2 case?

Thanks

Ryan


Ryan,
DMWDave has played with the idea but he reported on redline forum that the internals are different.
There is a way to fit mk2/3 diff housing in once you modify the outer bearing. But the rest of the box is not directly swapable.


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PostPosted: Sat Sep 16, 2006 1:46 am 
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The MK1 and the MK2/3 bellhousing patterns are identical. I've personally testfitted a MK3 GTi bellhousing onto an '88 Sprint engine, and everything lines up perfectly. Why not just use the MK1 tranny, and make new tranny mounts, and modify the driveshafts?

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jaguar,vettes&sprints wrote:
...can you inlighten me about lihtan's
( miracle pour hole)
maybe a picture Thanks


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PostPosted: Wed Mar 18, 2009 12:58 am 
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Just updating an old sticky with a link to Phil n Ed's mk1 disassembly how to guide.

http://www.teamswift.net/viewtopic.php?f=9&t=42589&p=321675#p321675

To answer a previous question, yes the mk1 gti does have the same 4 pinion diff as the mk1 turbo.


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PostPosted: Tue Nov 15, 2011 12:52 am 
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Zero of these links work for the manual. Error 404, not found is the message I get for all of them. :cry:


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PostPosted: Tue Nov 15, 2011 1:58 am 
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SOMEhow the link that i posted dissappeared.

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Silver 2000 Firefly 4DR; 16V SOHC, 3 to 5 speed swap, install PS and AC, remote and auto start, PL, PW, kill and start switch, Valentine 1, behind-bumper CAI, 55MM TB with coolant-bypass, polyurethane-fill engine/shifter mounts, modified to short shifter, upgraded electrical system, CS130 alternator, 90/160W headlights + relay mod, ceramic H4 plug/harness
To do: finish stereo, 4000K H4 HIDs, short block replacement
'sponsored' by Captain Crunch, Lordco, Felpro, Permatex, Royal Purple


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PostPosted: Tue Jul 02, 2013 4:54 am 
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Is the link to the pictures broken for this post?

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Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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