Fifth Gear Disassembly and Reassembly
Fifth Gear Disassembly and ReassemblyDisassembly
1. Remove cover bolts and take off transaxle side cover.
CAUTION: Care should be taken not to distort side cover when it is removed from left case.
2. Using snap ring pliers, remove circlip (1).
3. Remove shift fork shaft bolt (2).
4. Remove gear shift fork (3) and 5th gear all together. Use gear puller for removal if spline fitting of hub is tight.
5. Unfasten caulking of countershaft nut (2), install input shaft 5th gear (1) and special tool to stop rotation of shafts, and then remove countershaft nut (2).
Special Tool (A):09927-76060
6. Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would be necessary if spline fitting of countershaft 5th gear is tight.
Reassembly
1. Install countershaft 5th gear (1) to countershaft facing machined boss "A" inward.
2. Apply transaxle oil to needle bearing, and install it to input shaft.
3. Install input shaft 5th gear (1) to input shaft.
4. Install special tool in order to stop shaft rotation.
Special Tool (A):09927-76060
5. Tighten new countershaft nut (2) to specified torque, and caulk nut securely.
Tightening torque
Countershaft nut a: 100 Nm (10.0 kgf-m, 75.0 ft. lbs.)
6. Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and synchronizer ring (4) as follows.
a) Install hub (1) to 5th speed synchronizer sleeve (2) in specified direction as shown in figure.
b) Fit 5th speed synchronizer levers (1) to hub (2) in specified position as shown in figure.
NOTE: Align protrusion "A" of 5th speed synchronizer levers (1) with groove of hub (2).
c) Install synchronizer ring (1) to hub (2) in specified direction as shown in figure.
7. Fit 5th gear shift fork (1) to sleeve (3) and hub (2) assembly, and install them into input shaft and gear shift shaft, aligning punch mark (4) with matching mark (5) on input shaft.
8. Tighten shift fork shaft bolt (2) to which thread lock cement has been applied.
"A": Thread lock cement 99000-32110 Thread Lock Cement Super 1322
Tightening torque
Shift fork shaft bolt a: 10 Nm (1.0 kgf-m, 7.5 lb_ft)
9. Using snap ring pliers, install new circlip (1) to input shaft (3).
10. Clean mating surface of both left case and side cover (1), apply sealant to side cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate it with left case, and then tighten side cover bolts with specified torque.
"B": Sealant 99000-31260SUZUKI Bond No.1217G
Tightening torque
Side cover bolt a: 10 Nm (1.0 kgf-m, 7.5 ft. lbs.)
