Part 2
DIFFERENTIAL ASSEMBLY
Disassembly
1. Using special tool, remove R bearing.
Special Tool
(A): 09913 - 65810
(B): 09925 - 88210
2. Take out speedometer drive gear.
NOTE: In case that half-moon type puller is used with press for bearing removal, remove final gear in advance.
3. Remove L bearing by using puller while supporting its center shaft as described above.
4. Support differential case with soft jawed vise and remove 8 final gear bolts then take out final gear.
5. Using special tool and hammer, drive out differential side pinion shaft pin and then disassemble component parts.
Special Tool (C): 09922 - 85811 (4.5 mm)
Adjustment and Reassembly
Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that all parts are clean.
1. Assemble differential gear and measure thrust play of differential gear as follows.
Special Tool
(A): 09900 - 20606
(B): 09900 - 20701
Differential gear thrust play: 0.05 - 0.33 mm (0.002 - 0.013 inch)
Left side
- Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surface of gear.
- Using 2 screwdrivers, move gear up and down and read movement of dial gauge pointer.
Right side
- Using similar procedure to the above, set dial gauge tip to gear shoulder.
- Move gear up and down by hand and read dial gauge.
2. If thrust play is out of specification, select suitable thrust washer from among following available size, install it and check again that specified gear play is obtained.
3. Drive in spring pin from right side till it is flush with differential case surface.
4. Press-fit L bearing by using special tool and copper hammer.
Special Tool
(C): 09951 - 76010
(D): 09951 - 16060
5. Install speedometer drive gear, support differential assembly as illustrated so as to L bearing is floating, and then press-fit R bearing like L bearing in Step 4.
6. Hold differential assembly with soft jawed vise, install final gear and then tighten it with 8 bolts to specified torque.
CAUTION: Use of any other bolts than specified ones is prohibited.
Tightening Torque (a): 90 Nm (9.0 kg-m, 65.0 ft. lbs.)
ASSEMBLING UNIT
DIFFERENTIAL TO LEFT CASE
1. Install differential assembly into right case.
2. Insert speedometer driven gear case assembly applied with oil to its O-ring and gear, then tighten it with bolt.
CAUTION:
^ While inserting case assembly into transmission, turn final gear by hand slightly so that gear can mesh easily.
^ Never push or hit slit portion of case when inserting it. Such attempt may cause case to break.
Tightening Torque (a): 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)
3. Join input shaft, countershaft, low speed gear shift shaft and high speed gear shift shaft assemblies all together, then install them into right case.
NOTE:
^ Input shaft R bearing on shaft can be installed into right case by tapping shaft with plastic hammer.
^ Check to make sure that counter shaft is engaged with final gear while installing.
4. Install 5th & REV gear shift shaft with 5th & REV gear shift guide shaft into right case. Reverse gear shift arm has to be joined with reverse gear shift lever at the same time.
5. Make reverse idler gear with reverse gear shift lever, insert reverse gear shaft into case through idler gear and then align A in shaft with B in case.
NOTE:
^ Make sure that washer has been installed in shaft at above the gear.
^ Check to confirm that reverse gear shift lever end has clearance 1 mm (0.04 inch) to idler gear groove.
6. Clean mating surfaces of both right and left cases, coat mating surface of left case with sealant evenly then mate it with right case.
Sealant: SUZUKI BOND No.1215, 99000 - 31110
7. Tighten case bolts from outside to specified torque.
Tightening Torque (b): 19 Nm (1.9 kg-m, 14.0 ft. lbs.)
8. Install reverse shaft bolt with aluminum washer and tighten it.
Tightening Torque (c): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
9. Install another 2 case bolts from clutch housing side and tighten them to specification.
10. Check locating spring for deterioration and replace with new one as necessary.
11. Install steel ball and locating spring for respective gear shift shaft and tighten with bolt.
Tightening Torque (d): 13 Nm (1.3 kg-m, 9.5 ft. lbs.)
FIFTH GEARS
1. To seat countershaft L bearing cup to bearing cone, tap cup by using special tool and plastic hammer.
Special Tool (A): 09913 - 84510
2. Put a shim on bearing cup provisionally, place straight edge over it and compress it by hand through straight edge, and then measure "a" (Clearance between case surface and straight edge) by using feeler gauge.
Clearance "a": 0.08 - 0.12 mm (0.0032 - 0.0047 inch) (Shim protrusion)
3. By repeating above step, select a suitable shim which adjusts clearance "a" to specification and put it on bearing cup.
NOTE: Insert 0.1 mm (0.004 in) feeler to know whether or not a shim fulfills specification quickly.
4. Place left case plate inserting its end in groove of shift guide shaft and then tighten it with 6 screws applied with thread lock cement.
NOTE: After tightening screws, make sure that counter shaft can be rotated by hand feeling some load.
"A": Thread lock cement 99000 - 32110
Tightening Torque (a): 9 Nm (0.9 kg-m, 6.5 ft. lbs.)
5. Assemble 5th speed synchronizer sleeve and hub with keys arid springs.
NOTE: Short side C in keys, long boss D in hub and chamfered spline F in sleeve should face inward (5th gear side).
6. Install 5th gear to counter shaft facing machined boss A inward.
7. Install needle bearing to input shaft, apply oil then install 5th gear and special tool to stop shaft rotation.
Special Tool (B): 09927 - 76010
8. Install countershaft nut and tighten it to specification.
Tightening Torque (b): 70 Nm (7.0 kg-m, 51.0 ft. lbs.)
9. Remove special tool, then caulk nut at C with caulking tool and hammer.
10. Install synchronizer ring then ring spring.
11. Fit 5th gear shift fork to sleeve & hub assembly and install them into input shaft, shift shaft and shift guide shaft at once aligning hub oil groove A with shaft mark B.
NOTE: Long boss of hub faces inward (gear side).
CAUTION: Be careful not to pinch synchronizer ring spring by hub.
12. Drive in spring pin facing its slit A outward.
13. Install steel ball, tighten shift fork plug applied with thread lock cement.
"A": Thread lock 1322, 99000 - 32110
Tightening Torque (c): 9 Nm (0.9 kg-m, 6.5 ft. lbs.)
14. Fit hub plate and fix it with circlip.
CAUTION:
^ Coat shift fork plug with thread lock cement reasonably. If it is done to much, excess may interfere in ball movement and cause hard shift to 5th speed.
^ Make sure circlip is installed in shaft groove securely.
15. Clean mating surface of both left case and side cover, coat mating surface with sealant evenly, mate it with left case and then tighten with 8 bolts.
"B": Sealant 99000 - 31110
Tightening Torque for left cover bolts:
(a): 10 Nm (1.0 kg-m, 7.5 ft. lbs.)
(b): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
GEAR SHIFT & SELECT SHAFT ASSEMBLY
1. If gear shift guide case has been disassembled or replaced, tighten bolts as specified below. Also check breather hole for clog.
Tightening Torque
(a): 10 Nm (1.0 kg-m, 7.5 ft. lbs.)
(b): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
2. Clean mating surface of guide case and coat it with sealant evenly.
"A": Sealant 99000 - 31110
3. Install gear shift yoke and joint it with gear shift arm.
4. Install gear shift & select shaft assembly into transmission and joint its bottom end with gear shift yoke.
NOTE: When installing gear shift & select shaft assembly, position gear in neutral so that gear shift interlock plate will go in smoothly.
5. Tighten yoke and shaft with bolt applied with thread lock cement.
"B": Thread lock 1322, 99000 - 32110
Tightening Torque (c): 34 Nm (3.4 kg-m, 24.5 ft. lbs.)
6. Install gear shift interlock bolt with washer and tighten it to specification.
Tightening Torque (c): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
7. Clean mating surface of left case and put gear shift guide case applied with sealant on it.
Sealant: SUZUKI BOND No. 1215, 99000 - 31110
8. Place wiring harness clamp bracket and fasten it together with gear shift guide case.
Tightening Torque (d): 10 Nm (1.0 kg-m, 7.5 ft. lbs.)
9. Install back up light switch and clamp its lead.
Tightening Torque (e): 20 Nm (2.0 kg-m, 14.5 ft. lbs.)
10. Clean left case cap and mating surface of left case, check condition of O-ring and then fasten cap with 3 bolts.
Tightening Torque (d): 10 Nm 11.0 kg-m, 7.5 ft. lbs.)
11. Check input shaft for rotation in each gear position.
12. Also confirm function of back up light switch in reverse position by using ohmmeter.