Manual Transaxle Assembly Disassembly and Reassembly
Manual Transaxle Assembly Disassembly and ReassemblyDisassembly
1. Remove left case plate bolts (1), and take off left case plate (2).
2. Remove bearing set shim.
3. Remove snap ring (1) using snap ring pliers (4).
4. Remove gear shift locating bolts (1), then take out locating springs and steel balls.
5. Remove reverse shaft bolt (2) with washer.
6. Remove transaxle case bolts (1) from outside and another bolts from clutch housing side.
7. Tapping left case flanges with plastic hammer, remove left case.
8. Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3).
9. Remove reverse gear shift lever bolts (4) and reverse gear shift lever (5).
10. Pull out 5th & reverse gear shift guide shaft (6) together with 5th & reverse gear shift shaft (7).
NOTE: When removing 5th & reverse gear shift shaft (7) and guide shaft (6), push up high speed gear shift shaft and shift it to 4th to facilitate removal of 5th & reverse shift shaft.
11. Tapping input shaft end with plastic hammer, push it out as assembly from case a little, then take out input shaft assembly (1), countershaft assembly (2), high speed gear shift shaft (3) and low speed gear shift shaft (4) all at once.
12. Remove countershaft left bearing outer race from left case.
13. Remove differential assembly from right case.
Reassembly
1. Install differential assembly into right case.
2. Join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft (3) assemblies all together, then install them into right case (1) so as not to damage oil seal by input shaft spline.
NOTE:
^ Input shaft right bearing on shaft can be installed into right case (1) by tapping shaft with plastic hammer.
^ Make sure that countershaft is engaged with final gear while installing.
3. Install 5th & reverse gear shift shaft (1) with 5th & reverse gear shift guide shaft (2) into right case (5). Reverse gear shift arm (4) has to be joined with reverse gear shift lever (3) at the same time.
4. Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) and washer (6) into case (4) through idler gear and then align bolt hole "a" in shaft with notch "b" in case.
5. Fasten reverse gear shift lever bolts (5) after applying thread lock cement.
"A": Thread lock cement 99000-32110 Thread Lock Cement Super 1322
Tightening torque
Reverse gear shift lever bolt a: 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
NOTE: Check to confirm that reverse gear shift lever end has clearance "c" to idler gear groove.
Distance between lever end and idler gear shaft "c": 0.5 - 1.0 mm (0.02 - 0.04 in.)
6. Clean mating surfaces of both right and left cases, apply sealant to left case (2) as shown in the figure by such amount that its section is 1.5 mm (0.059 in.) in diameter then mate it with right case (1).
"A": Sealant 99000-31260SUZUKI Bond No.1217G
7. Tighten case bolts (3) from outside and tighten another case bolts from clutch housing side to specified torque.
Tightening torque
Transaxle case bolt a: 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
8. Install reverse shaft bolt (4) to which thread lock cement has been applied, with aluminum washer and tighten it to specified torque.
"B": Sealant 99000-31260SUZUKI Bond No.1217G
Tightening torque
Reverse shaft bolt b: 21 Nm (21 kgf-m, 15.5 ft. lbs.)
9. Check locating springs (2, 4 and 5) for deterioration and replace with new ones as necessary.
Locating spring
10. Install steel balls (3) and locating springs (2, 4 and 5) for respective gear shift shaft and tighten bolts (1) to which thread lock cement has been applied.
"'A": Thread lock cement 99000-32110 Thread Lock Cement Super 1322
Tightening torque
Gear shift locating bolt a: 13 Nm (1.3 kgf-m, 9.5 ft. lbs.)
11. Install new snap ring (1) using snap ring pliers (4).
12. To seat countershaft left bearing outer race (2) to bearing cone, tap cup by using special tool and plastic hammer.
Special Tool (A):09913-70123
13. Before selecting shim, keep pushing outer race with the power of 100 N (10.0 kgf) and turn countershaft (2) 10 time or more.
14. Put a shim (3) on bearing outer race (4) provisionally, place straight edge (1) over it and compress it by hand through straight edge, and then measure "a" (Clearance between case surface (5) and straight edge) by using feeler gauge (6).
Clearance between case surface and straight edge "a": 0.08 - 0.13 mm (0.0032 - 0.0050 in.)
15. By repeating step 14), select a suitable shim which adjusts clearance "a" to specification and put it on bearing outer race.
NOTE: Insert 0.1 mm (0.004 in.) feeler to know whether or not a shim fulfills specification quickly.
Available countershaft 5th gear shim thickness
16. Place left case plate (2) inserting its end in groove of shift guide shaft (4) and then tighten bolts (1) to which thread lock cement has been applied.
NOTE: After tightening bolts, make sure that countershaft can be rotated by hand feeling certain load.
"A": Thread lock cement 99000-32110 Thread Lock Cement Super 1322
Tightening torque
Left case plate bolt a: 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
