Reassembly

Manual Transmission Unit Reassembly

Manual Transmission Assembly Components

Manual Transmission Unit Disassembly

Locating Spring Inspection
1) 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).

NOTE:
Oil leaks will occur if the oil seal lip is damaged.

Be careful not to damage the oil seal lip when inserting the input shaft into the front case.





2) Install new input shaft front bearing snap ring (1) using special tool.
Special Tool

(A): 09900-06106





3) Install low speed gear shift shaft (1) and low gear shift inverse lever (2) and tighten with new bolt (3).

NOTE:
The inverse lever bolt is pre-coated with adhesive. If the bolt is reused, it may work loose.

Never reuse the inverse lever bolt.

Tightening torque
Low gear shift inverse lever bolt (a): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)





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 in.) in diameter, and then mate it with rear case.

"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)





10) Install rear case to front case. Tighten case bolts (1) to specified torque.

Tightening torque
Transmission case bolt (a): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

11) Install new reverse shaft bolt (2) and new washer, and tighten it to specified torque.

NOTE:
The reverse shaft bolt is pre-coated with adhesive. If the bolt is reused, it may work loose.

Never reuse the reverse shaft bolt.

Tightening torque
Reverse shaft bolt (b): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

12) Install back up light switch (3) referring to Back Up Light Switch Removal and Installation Back Up Light Switch Removal and Installation.





13) Apply grease to locating balls (1) and locating springs (2), then install them.

Tighten new gear shift locating bolts (3) to specified torque.

NOTE:
The shift locating bolt is pre-coated with adhesive. If the bolt is reused, it may work loose.

Never reuse the shift locating bolt.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)

Tightening torque
Gear shift locating bolt (a): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)





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 (4) 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






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 in.) in diameter, and then mate it with adapter case.

"A" Sealant: 99000-31260 (SUZUKI 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 kgf-m, 17.0 lbf-ft)





19) Install transfer assembly or extension case assembly to transmission assembly. Tighten transfer or extension case fastening bolts to specified torque referring to Components Transfer Assembly Components:Motor-Shift Type (Transfer with Shift Actuator) or Extension Case Assembly Components Extension Case Assembly Components.
20) Install gear shift lever front case assembly referring to Gear Shift Lever Front Case Assembly Removal and Installation Gear Shift Lever Front Case Assembly Removal and Installation.
21) Install clutch operating cylinder assembly to transmission front case referring to Clutch Operating Cylinder Assembly Removal and Installation Clutch Operating Cylinder Assembly Removal and Installation.