Manual Transaxle Removal and Installation

DISMOUNTING OF TRANSMISSION
Under Hood
1. Disconnect battery ground cable.
2. Remove battery and its tray. (1.3 liter engine model only)
3. Remove clutch cable joint nut, joint pin from cable and then cable itself from bracket.
4. Undo wiring harness clamps and couplers.
5. Take off speedometer cable boot, speedometer case clip and then speedometer cable from case.
6. Detach radiator outlet pipe from transmission side cover. (1.3 liter engine model only)
7. Remove transmission fastening bolts.
8. Remove starter taking out its 2 bolts. Starting motor plate should also come down.

On Lift





1. Drain transmission oil. Special tool (10 mm hexagon socket) and ratchet wrench are applicable.
2. Remove fender apron extension of left side.
3. Remove exhaust pipe nuts to disconnect their joint.
4. Remove gear shift control shaft bolt and nut, then detach control shaft from gear shift shaft.
5. Remove extension rod nut and then pull out rod with washers.
6. Remove clutch housing lower plate. Disconnect stabilizer joint from suspension arm.
7. Remove ball stud bolt from right and left knuckles, then disconnect each suspension arm.





8. By using large size screwdrivers, pull out drive shaft joints at differential side so as to release snap ring fitting of joint. (for other than RH drive shaft of 1.3 liter engine model)





9. Remove center bearing support bolts and pull out center drive shaft from differential gear. (for RH drive shaft of 1.3 liter engine model)
10. Remove transmission stiffener.
11. Remove transmission to engine bolt and nut.
12. Remove engine rear mounting bracket bolts.
13. Lower vehicle and support engine with hoist.
14. Support transmission with transmission jack.





15. Remove engine mounting LH bracket and its stiffener.
16. Other attached parts from transmission, if any.
17. Pull transmission out so as to disconnect input shaft from clutch disc and then lower it.

REMOUNTING
For remounting, reverse dismounting procedure.





Use specified torque as shown.

NOTE: Apply grease to gear shift control shaft bushes, however, DO NOT lubricate extension rod bush.

CAUTION:
^ Care should be taken not to scratch oil seal lip with drive shaft while raising transmission.
^ Do not hit drive shaft joint with hammer when installing it into differential gear.

- Before installing engine rear mounting bracket bolt (upper side), apply sealant (SUZUKI BOND No. 1215) to its thread.
- Push in left side drive shaft joint fully so as to snap ring of shaft engages with differential gear.
- Set each clamp for wiring securely.





- After connecting clutch cable, be sure to adjust its play properly.

Arm play "a": 0 - 2 mm (0 - 0.08 inch)
[Pedal play "a": 15 - 20 mm (0.6 - 0.8 inch)]

- Fill transmission with oil as specified.
- Connect battery and check function of engine, clutch and transmission.