Manual Transmission Unit Reassembly
Manual Transmission Unit Reassembly1) Assemble input shaft assembly (1), countershaft assembly (2), high speed gear shift fork (3) and low speed gear shift fork (4), then install them all together into front case (5).
CAUTION:
Take care not to damage oil seal lip by input shaft, or oil leakage may take place.
2) Install new input shaft front bearing snap ring (1) using special tool.
Special Tool
(A): 09900-06106
3) Install low speed gear shift shaft (1) and low gear shift inverse lever (2) and tighten with new bolt (3).
CAUTION:
Be sure to use new bolts with pre-coated adhesive. Otherwise, bolts may loosen.
Tightening torque
Low gear shift inverse lever bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
4) Fit 5th & reverse gear shift fork (1) to 5th speed synchronizer sleeve (2), and install them into input shaft and front case in specified direction as shown in figure.
5) Set reverse idler gear (1), reverse gear shift lever (2) and reverse gear shaft washer (4), insert reverse gear shaft (3) into case through idler gear and then align hole "B" in shaft with protrusion "A" in case.
6) Install oil gutter.
7) Install 5th speed synchronizer levers and 5th speed synchronizer ring as follows.
a) Fit 5th speed synchronizer levers (1) to hub (2) aligning protrusion "A" of 5th speed synchronizer levers with groove of hub.
b) Install synchronizer ring (1) to hub (2) in specified direction as shown in figure.
8) Install input shaft needle bearing to end of input shaft.
9) Clean mating surfaces of both front and rear cases, and uniformly apply sealant to front case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, and then mate it with rear case.
"A": Sealant 99000-31260 (SUZUKI Bond No.1217G)
10) Install rear case to front case. Tighten case bolts (1) to specified torque.
Tightening torque
Transmission case bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
11) Install new reverse shaft bolt (2) and new washer, and tighten it to specified torque.
CAUTION:
Be sure to use new bolts with pre-coated adhesive. Otherwise, bolts may loosen.
Tightening torque
Reverse shaft bolt (b): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
12) Install Backup Light switch (3).
13) Apply grease to locating balls (1) and locating springs (2), then install them.
Tighten new gear shift locating bolts (3) to specified torque.
CAUTION:
Be sure to use new bolts with pre-coated adhesive. Otherwise, bolts may loosen.
"A": Grease 99000-25011 (SUZUKI Super Grease A)
Tightening torque
Gear shift locating bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
14) Install output shaft assembly into rear case.
15) Select a countershaft shim and output shaft shim as follows.
a) Measure depth "a" from mating surface of adapter case (1) to face processed for installation of countershaft rear bearing (2) and measure depth "c" from mating surface of adapter case to face processed for installation of output shaft rear bearing (5) using fernier caliper.
b) Measure height "b" from mating surface of rear case (3) to countershaft rear bearing (4) and "d" from mating surface of rear case (3) to output shaft bearing (6) using fernier caliper.
c) Calculate "a" - "b" and "c" - "d", and select a shim according to the following table.
Countershaft shim selection table
Output shaft shim selection table
16) Install selected countershaft shim and output shaft shim to adapter case.
17) Clean mating surface of both rear case (1) and adapter case, and uniformly apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, and then mate it with adapter case.
"A": Sealant 99000-31260 (SUZUKI Bond No.1217G)
18) Install rear case to adapter case. Tighten case bolts (2) to specified torque.
Tightening torque
Adapter case bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
19) Install transfer assembly or extension case assembly to transmission assembly. Tighten transfer or extension case fastening bolts to specified torque.
20) Install gear shift lever front case assembly.
21) Install clutch operating cylinder assembly to transmission front case.