Manual Transmission Unit Reassembly
Manual Transmission Unit Reassembly1. Assemble input shaft assembly (1), countershaft assembly (2), high speed gear shift fork (3) and low speed gear shift fork (4), then install them all together into front case (5).
CAUTION: Take care not to damage oil seal lip by input shaft, or oil leakage may take place.
2. Install input shaft front bearing snap ring (1) using special tool.
3. Install low speed gear shift shaft (1) and low gear shift inverse lever (2) and tighten with new bolt (3).
Tightening torque
Low gear shift inverse lever bolt a: 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
4. Fit 5th & reverse gear shift fork (1) to 5th speed synchronizer sleeve (2), and install them into input shaft and front case in specified direction as shown in figure.
5. Set reverse idler gear (1), reverse gear shift lever (2) and reverse gear shaft washer (4), insert reverse gear shaft (3) into case through idler gear and then align hole B in shaft with protrusion A in case.
6. Install oil gutter.
7. Install 5th speed synchronizer levers and 5th speed synchronizer ring as follows.
a. Fit 5th speed synchronizer levers (1) to hub (2) aligning protrusion A of 5th speed synchronizer levers with groove of hub.
b. Install synchronizer ring (1) to hub (2) in specified direction as shown in figure.
8. Install input shaft needle bearing to end of input shaft.
9. Clean mating surfaces of both front and rear cases, and uniformly apply sealant to front case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 inch) in diameter, and then mate it with rear case.
10. Install rear case to front case. Tighten case bolts (1) to specified torque.
Tightening torque
Transmission case bolt a: 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
11. Apply thread lock cement to reverse shaft bolt (2), and tighten it.
B: Thread lock cement 99000-32110Thread Lock Cement Super 1322
Tightening torque
Reverse shaft bolt b: 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
12. Install back up light switch (3).
13. Apply grease to gear shift shaft balls (1) and locating springs (2), then install them. Apply thread lock cement to gear shift locating bolts (3), and then tighten them.
14. Install output shaft assembly into rear case.
15. Select a countershaft shim and output shaft shim as follows.
a. Measure depth a from mating surface of adapter case (1) to face processed for installation of countershaft rear bearing (2) and measure depth c from mating surface of adapter case to face processed for installation of output shaft rear bearing (5) using vernier caliper.
b. Measure height b from mating surface of rear case (3) to countershaft rear bearing (2) and d from mating surface of rear case (3) to output shaft bearing (6) using vernier caliper.
c. Calculate a-b and c-d, and select a shim according to the following table.
Countershaft shim selection table
Countershaft shim selection table:
Output shaft shim selection table
Output shaft shim selection table:
16. Install selected countershaft shim and output shaft shim to adapter case.
17. Clean mating surface of both rear case (1) and adapter case, and uniformly apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 inch) in diameter, and then mate it with adapter case.
A: Sealant 99000-31260SUZUKI Bond No.1217G
18. Install rear case to adapter case. Tighten case bolts (2) to specified torque.
Tightening torque
Adapter case bolt a: 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
19. Install transfer assembly or extension case assembly to transmission assembly. Tighten transfer or extension case fastening bolts to specified torque
20. Install gear shift control lever rear case assembly and gear shift lever front case assembly.
21. Install clutch operating cylinder assembly to transmission front case.