M/T - Shift Lever Vibration In 3rd Gear

Division: Automotive

Category: Technical

Section Title: Transmission/Transaxle

TSB No.: TS 02 05128

SUBJECT:
GEAR SHIFT LEVER VIBRATION IN 3RD GEAR

MODEL(S):
SX4 (RW420) MANUAL TRANSMISSION ONLY

YEAR:
2007-2008

CONDITION:

Abnormal vibration at the gear shift lever can be felt while driving in 3rd gear.

CAUSE:

Gear train vibration is transmitted through the gear shift cable into the gear shift lever.

CORRECTION:

A modified internal gear shift lever is available to help isolate the above condition.

Please follow the service manual procedure to remove and install the gear
shift and selector shaft lever, without removing the transmission from the vehicle. Refer to attached tips for a smooth removal and installation process.





PART(S) INFORMATION





WARRANTY CLAIM INFORMATION

Removal and Install Tips:

Step 3 of "Removal"








Interlock and guide bolts can be accessed from the engine compartment or left front wheel well.








To remove the top shift cable, remove the plastic clip and slide the cable up away from the lever.

Lift the gear shift select shaft up then angle toward the front of the vehicle to remove from transmission.

GEAR SHIFT AND SELECT SHAFT ASSEMBLY REMOVAL AND INSTALLATION

Removal





1) Remove battery and tray with ECM.

2) Disconnect gear shift and gear select control cables from transaxle.

3) Remove gear shift interlock bolt (1) and 5th to reverse interlock guide bolt (2) from transaxle case.

4) Remove gear shift & select shaft assembly (3).

Installation





1) Clean mating surface of guide case (1) and left case (5), apply sealant to left case as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate guide case with left case.

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

2) Install guide case bolts No. 1 to which thread lock cement has been applied and guide case bolts No. 2 (2), and tighten them to specified torque.

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

Tightening torque

Guide case bolt No. 1: 23 Nm (2.3 kgf-m, 17.0 lbft)

Guide case bolt No. 2 (a): 23 Nm (2.3 kgf-m, 17.0 lb-ft)

3) Install washer and gear shift interlock bolt (3) to which thread lock cement has been applied and then tighten it to specified torque.

"A": Sealant 9900031260 (SUZUKI Bond No.1217G)

Tightening torque

Gear shift interlock bolt (b): 23 Nm (2.3 kgf-m, 17.0 lb-ft)

4) Install washer and 5th to reverse interlock guide bolt (4) to which thread lock cement has been applied and then tighten it to specified torque.

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

Tightening torque

5th to reverse interlock guide bolt (c): 23 Nm (2.3 kgf-m, 17.0 lb-ft)

5) Connect gear shift and gear select control cables to transaxle.

6) Install battery and tray with ECM.

7) Check input shaft for rotation in each gear position.

GEAR SHIFT AND SELECT SHAFT ASSEMBLY DISASSEMBLY AND REASSEMBLY

1) Push spring pins out using 2.8 - 3.0 mm (0.11 - 0.12 in.) commercially available spring pin remover and specified spring pin removers as shown below.

Special tool

(A): 09922-85811 4.5 mm

(B): 09925-78210 6.0 mm

2) Inspect component parts for wear, distortion or damage. If any detect is found, replace detective part with new one.














NOTE:
^ When driving in spring pins, prevent shaft from being bent by supporting it with wood block.

^ Assemble 5th & reverse gear shift cam with its pit and spring pin aligned.

^ Make sure to select an appropriate spring by identifying the painted colors to keep gear shifting performance as designed.

- Low speed select spring - No paint

- Reverse select spring - Pink





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