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Home >> Suzuki >> 1995 >> Sidekick JS, 2D Utility, Automatic, 03-73LE >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - 5-Speed >> Component Disassembly & Reassembly >> Lower Case Assembly >> Reassembly
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Lower Case Assembly: Reassembly

  1. Install friction gear, spring, pin, retainer and circlip to countershaft. Install front countershaft bearing and circlip onto countershaft. See Fig 3 . Install countershaft center bearing onto countershaft. Press countershaft and center bearing into lower case. See Fig 4 . Install outer circlip to front countershaft bearing. Position countershaft so front countershaft bearing makes slight contact with lower case.
  2. Apply Loctite to countershaft center bearing plate bolts. Position plate into lower case and secure with 2 bolts. Torque to 53 INCH lbs. (6 N.m).
  3. Install reverse idler gear, needle bearing and thrust washer onto reverse idler shaft. Apply Loctite to threaded portion of reverse idler shaft bolt. Install reverse idler gear assembly into lower case and secure with washer (aluminum) and bolt. Torque bolt to 16 ft. lbs. (22 N.m).
  4. Install countershaft reverse and 5th gears onto countershaft. Using bearing installers, install rear countershaft bearing.
Fig 1: Exploded View Of Countershaft & Reverse Shaft Assemblies
G93A24273Courtesy of GENERAL MOTORS CORP.
Fig 2: Exploded View Of Countershaft Friction Gear Assembly
G93B24274Courtesy of GENERAL MOTORS CORP.
Fig 3: Installing Countershaft Front Bearing
G93C24275Courtesy of GENERAL MOTORS CORP.
Fig 4: Installing Center Bearing
G93D24276Courtesy of GENERAL MOTORS CORP.