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Transaxle Reassembly

  1. Install reverse gear shift lever. Apply Loctite (1052624) to bolts and install bolts loosely. Measure and set lever end .2" (5 mm) from reverse gear shaft bore. See Fig 6. Torque bolts to 17 ft. lbs. (23 N.m).
  2. Install input shaft oil seal with spring side upward using Oil Seal Installer (Geo J34855, Suzuki 09951-76010). Install countershaft RH bearing race using Bearing Race Installer (Geo J34849, Suzuki 09925-68210) with Driver Handle (Geo J7079-2, Suzuki 09924-74510). See Fig 6.
  3. Apply grease to gear shift shaft oil seal lip and install, spring side toward case, using Gear Shift Shaft Seal Installer (Geo J34857, Suzuki 09925-58210). Install gear shift shaft, boot, steel ball, spring and washer. See Figure. Apply sealant to bolt and torque to 10 ft. lbs. (14 N.m).
  4. Install boot over oil seal. Install gear shift shaft inner oil seal with spring side toward case. Install differential RH oil seal and torque bolt with washer flush with case. Apply grease to seal lip.
  5. Install gear shift arm onto gear shift shaft. Drive in roll pin coated with Loctite. Install magnet to case. Install oil gutter. See Figure. Coat bolt threads with Loctite and torque to 53 INCH lbs. (6 N.m).
    Fig 1: Identifying 1st & 2nd Synchronizer Ring
    G93F24856Courtesy of GENERAL MOTORS CORP.
    Fig 2: Exploded View Of Gear Shift & Select Shaft Assembly
    G93G24857Courtesy of GENERAL MOTORS CORP.
  6. Apply grease to differential side LH oil seal lip. Install seal with spring side toward case using Axle Shaft Seal Installer (Geo J29130, Suzuki 09913-75510) and Driver Handle (Geo J8092, Suzuki 09924-74510). Install countershaft LH bearing race by tapping lightly with plastic hammer.
  7. Install differential assembly flush into right case. Coat speedometer driven gear case assembly "O" ring with oil and install to case. Torque bolt to 53 INCH lbs. (6 N.m).
  8. Assemble input shaft and countershaft together with high and low speed gear shift shaft assemblies. Install into right case. See Fig 7. Ensure countershaft is engaged to final gear.
    Fig 3: Exploded View Of Low & High Speed Shifter Assemblies
    G93H24858Courtesy of GENERAL MOTORS CORP.
    Fig 4: Exploded View Of 5th & Reverse Shifter Assembly
    G93I24859Courtesy of GENERAL MOTORS CORP.
    Fig 5: Measuring Side Gear Thrust Play
    G93B24860Courtesy of GENERAL MOTORS CORP.
    Fig 6: Installing Reverse Gear Shift Lever
    G93C24861Courtesy of GENERAL MOTORS CORP.
    Fig 7: Installing Input Shaft & Countershaft
    G93D24862Courtesy of GENERAL MOTORS CORP.
    Fig 8: Installing & Aligning Reverse Gear Shaft
    G93E24863Courtesy of GENERAL MOTORS CORP.
  9. Install 5th and reverse gear shift shaft with 5th and reverse gear shift guide shaft. See Figure. Join reverse gear shift arm to reverse gear shift lever.
  10. Install reverse idler gear with reverse gear shift lever and insert reverse gear shaft with washer into case through idler gear. Align shaft mark "A" with case mark "B". See Fig 8.
  11. Clean mating surfaces of left and right cases. Coat mating surface of left case with sealant and install to right case. Install 11 outside case bolts and torque to 14 ft. lbs. (19 N.m). See Figure. Install reverse shaft bolt and aluminum washer and torque to 10 ft. lbs. (14 N.m). Install 2 inside case bolts and torque to 14 ft. lbs. (19 N.m).
  12. Inspect shift shaft detent springs for deterioration or deformation. See SHIFT SHAFT DETENT SPRINGS LENGTH  table. Replace with new springs as necessary. Install steel balls, spring, washers and bolts. See Fig 9. Torque gear shift shaft fork bolts to 10 ft. lbs. (14 N.m).
    SHIFT SHAFT DETENT SPRINGS LENGTH

    Spring Length In. (mm)
    Low Speed Spring
    Standard Length 1.028 (26.10)
    Service Limit .984 (25.00)
    High Speed Spring
    Standard Length 1.579 (40.10)
    Service Limit 1.535 (39.00)
  13. Install countershaft LH bearing race to bearing using Bearing and Seal Installer (Geo J35425, Suzuki 09913-84510). Select suitable shim to adjust clearance "A". See Fig 10. Install shim on bearing race. Place Flat Gauge Bar (Geo J34673) over it and compress. Measure "A" using feeler gauge. Clearance should be .0031-.0047" (.080-.120 mm).
  14. Install left case plate inserting end in groove of shift guide shaft. See Fig 11. Apply Loctite to screws and torque to 62 INCH lbs. (7 N.m). Ensure countershaft can be rotated by hand.
    Fig 9: Installing Locating Spring
    G93F24864Courtesy of GENERAL MOTORS CORP.
  15. Install 5th gear to countershaft facing machined boss inward. Install needle bearing to input shaft, apply oil and install 5th gear. Install Lock Nut Wrench (Geo J37975, Suzuki 09927-76010) to stop shaft rotation. Install lock nut and torque to 52 ft. lbs. (70 N.m).
  16. Remove lock nut wrench and stake lock nut. Install synchronizer ring and ring spring. See Fig 12. Install 5th gear shift fork to sleeve and hub assembly. Install onto input shaft, No. 1 shift shaft and shift guide shaft, aligning hub oil groove "A" with shaft mark "B".
  17. Drive in roll pin facing slit in pin outward. See Figure. Install guide ball and apply Loctite lightly to shift fork plug threads. Install plug and torque to 10 ft. lbs. (14 N.m). Install hub plate and snap ring. Ensure snap ring is installed securely.
  18. Clean mating surfaces of left case and left cover. Apply sealant to left cover mating surface evenly. Install left cover and torque bolts to 89 INCH lbs. (10 N.m).
  19. Install gear shift yoke and join to gear shift arm. See Figure. Install gear shift and select shaft assembly and join its bottom end to gear shift yoke. Apply Loctite to yoke and shaft bolt threads and torque to 17 ft. lbs. (23 N.m). Install gear shift interlock bolt with washer and torque to 17 ft. lbs. (23 N.m).
  20. Clean mating surfaces of left case and shift guide case. Apply sealant to shift guide case. Install shift guide case with wiring harness clamp and torque bolts to 89 INCH lbs. (10 N.m). See Fig 13.
  21. Install back-up light switch, torque to 15 ft. lbs. (20 N.m) and clamp its lead. Clean left case cap and left case mating surfaces. Install cap with ring and torque bolts to 89 INCH lbs. (10 N.m).
Fig 10: Selecting Bearing Set Shim
G93G24865Courtesy of GENERAL MOTORS CORP.
Fig 11: Installing Left Case Plate
G93H24866Courtesy of GENERAL MOTORS CORP.
Fig 12: Installing 5th Gear Sleeve & Hub
G93I24867Courtesy of GENERAL MOTORS CORP.
Fig 13: Installing Gear Shift Guide Case
G93J24868Courtesy of GENERAL MOTORS CORP.
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