1.6 manual gearbox to a v6 h20a bellhousing.

[escudoboy99]

hey all. I'm wanting to find out if a 1.6 vitara 5 speed manual gbox of any year between 93ish to 99ish, would bolt to a v6 bellhousing that bolts on to an h20a engine. The Gearboxes look pretty much identical but am unsure of the bolt pattern on the box and the input shaft length and spline. Its hard to find a v6 manual gearbox around as 95% of them are autos

Id be happy if anyone knows anything about them that can help me sort this problem out. cheers all!! and merry Christmas to all

[Tarmac]

I imagine the box end of it will work but the eng side of the housing will probably be different eg one is h the other g series block.

[escudoboy99]

Yea you are right tarmac. I pretty postive that the v6 bellhousing will fit on the 1.6 gearbox but am unsure about the spline and shaft size.

[Tarmac]

I get what your doing now, I know the early 3speed autos were common across many cars (the 1.6 vits being one of the smallest) and I believe the aw 4speed autos were common between the later 1.6 and v6 models. However the man boxes are probably made by a different company to the auto. I have a late (00?) 1.6 clutch ass and flywheel floating round if that helps - my guess is the spline etc is the same, maybe the dia of the fly etc may vary and shaft length is std and being set by the bell housing itself. If you can find some numbers on the box try google.

Hope this is helpful

[escudoboy99]

I'm thinking that i could even run a 1.6 vitara clutch if i had too. I think that the size of clutch is different between the two models. If i had a 1.6 gbox place side by side and compare them, things would be good. I have already fitted my skimmed flywheel and new clutch to my wagon, also am in the process off rebuilding the v6 manual box. Just want to put another box in for now and see if the gearing is different. Thanks for the information tarmac! Helps alot, if you are able to could you count the spline in the centre of the clutch where the input shaft goes through, then I could match the count to my clutch, which will tell me if they are the same.

Cheers

[crzyfl]

Where are you?
I've got a spare manual box

[escudoboy99]

Hey crzyfl I am in albany on the northshore in auckland. Is the gbox you have a v6 box or just a 1.6 vitara box. cheers

[escudoboy99]

I have matched up my box with a 1.6 box and the things that i need to change to be able to fit the box is the bearing retainer cover on the input side face along with the bell housing. I need to extend the input shaft by around 60mm to make it reach and fit. the front and rear drive shafts need to be swapped from v6 to 1.6 shaft too. Should have to shaft extended by the start of the week and welded on then to see if it will go in!!

[dan88]

would be interested to hear how you got on with the 1.6 gear box as I have just brought a V6 which i think has some gearbox issues

[escudoboy99]

Hey there dan. I managed to get the 1.6 gearbox to work with my v6 vitara. The bellhousing from the v6 gearbox bolted straight up, aslo had to change the cover on the input shaft of the gearbox with the v6 cover because of the clutch setup. Had to weld an extension on to the input shaft of the 1.6 to make it longer so it would reach through the clutch and sit in the spigot bearing inside the flywheel .my v6 The extra parts that needed to be swapped were the driveshafts which was easy enough to get from a wrecker. One disadvantage about the 1.6 gearboxes is that the shafts that run through them are smaller because there was less power in the 1.6L engines.

I am currently in the stage of rebuilding my v6 transfer box as I have just rebuilt my v6 gearbox! More progress to be made

If you need any advice let me know or give me a PM on here cheers

[dan88]

I have got my gearbox out and stripped it down to individual parts, I was just going to replace all the bearings including the needle bearings will this be enough and do you think its worth doing the transfer case at the same time?

cheers

[escudoboy99]

What I ended up replacing in my V6 gearbox was the main and second shaft bearings, one needle roller bearing that goes between the input shaft and output shaft as that is an important bearing, takes up the play on the input shaft. It was going to be too costly for me to replace all of the needle roller bearing as they aren't cheap, it all came from winger. Auckland bearings supplied me all of the seals I needed and were far cheaper then winger. The 1st & 2nd syncro where crunching so replaced those because I normally use those 2 gears the most when off road.

Am In the process of rebuilding my transfer box because I suspected a knocking sound coming from It. Some components inside are worn and have gotten eaten at so will see If I can locate a good 2nd hand T-Box from a V6.

Hoping to get it back together soon and back in the zuki as the 1600 box Is getting stuffed from abuse it gets!!

Hope this helps mate

Cheers

[gary_in_nz]

Hey there I got a work mate who was wondering about transfer case gears. He has a 95 v6 escudo manual, has 5.125 ratio diffs from a 1.6 but was after some low range gearing. Are the 1.6 or other vitara models have lower transfer gears than the v6? He has been finding low range first has too much wheel speed for any crawling or steep descents. Cheers

[zukmeista]

No, however there are transfer gears available from the U.S. to reduce low range, as seen here http://www.lowrangeoffroad.com/index.php/suzuki/sidekick-tracker-x90/drivetrain/sidekick-tracker-vitara-4-24-1-rockmonster-transfer-case-gears.html However not sure if they will fit the V6 transfer case, here are some threads I found on the subject. Hope this is helpful.
http://www.auszookers.com/forum/viewtopic.php?f=5&t=44139&hilit=V6+Vitara+Transfer+gears
http://www.auszookers.com/forum/viewtopic.php?f=5&t=43635&hilit=V6+Vitara+Transfer+gears
http://www.auszookers.com/forum/viewtopic.php?f=5&t=39408&hilit=V6+Vitara+Transfer+gears
http://www.auszookers.com/forum/viewtopic.php?f=17&t=37559&hilit=V6+Vitara+Transfer+gears