Transmission Reassembly
NOTE:
Apply SAE 75W-90 transmission fluid to components prior to installation.
- Install mainshaft and input shaft assembly into lower case. Ensure smooth engagement with countershaft. Shift all gears to neutral. Apply Sealant (GM 1052917 or Suzuki 99000-31110) to upper and lower case halves. Install upper case to lower case and torque bolts to 17 ft. lbs. (23 N.m).
- Apply sealant to input shaft bearing retainer and bolts. Install retainer and torque bolts to 17 ft. lbs. (23 N.m). For 2WD models, go to next step. For 4WD models, install rear case main seal using Seal Installer (Geo J37750 or Suzuki 09913-75510) with Driver Handle (Geo J8092). See Fig 1 . Go to step 4.
- On 2WD, install rear extension case oil seal using Seal Installer (Geo J37771 or Suzuki 09951-16060). Apply grease and install select guide pins, select return springs and spring bolts. See Figure . Tighten bolts to 17 ft. lbs. (23 N.m). Ensure each pin moves smoothly. Install speedometer driven gear assembly into extension case.
- Clean rear case/extension case and transmission mating surfaces. Apply sealant to mating surfaces and install on trans-mission. Torque bolts to 20 ft. lbs. (28 N.m) on 2WD models and to 17 ft. lbs. (23 N.m) on 4WD models.
- Clean gear shift lever case and rear case/extension case mating surfaces. Apply sealant to shift lever case, install and torque bolts to 13 ft. lbs. (17 N.m). Install clutch housing and bolts. Torque to 17 ft. lbs. (23 N.m). Install clutch release bearing.