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Transaxle Reassembly

  1. Install reverse gear shift lever. Apply Loctite 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. Install countershaft RH bearing race. See Fig 6.
  3. Apply grease to gear shift shaft oil seal lip and install, spring side toward case. 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 102 INCH lbs. (12 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. Install countershaft LH bearing race by tapping lightly with plastic hammer.
  7. Assemble input shaft and countershaft together with high and low speed gear shift shaft assemblies. Install into right-side case. See Fig 7. Ensure countershaft is engaged to final gear.
  8. Coat speedometer driven gear case assembly "O" ring with oil and install to case. Torque bolt to 53 INCH lbs. (6 N.m). Install differential assembly flush into right-side case. Rotate differential assembly to ensure speedometer drive gear meshes with speedometer driven 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 into right-side case. 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. Install gear shift yoke to gear shift arm. Clean mating surfaces of left and right-side cases.
  11. Coat mating surface of left-side case with sealant and install to right-side case. Install 2 case bolts inside right-side case (clutch housing) and 11 case bolts to outside of left-side case and torque to 16 ft. lbs. (22 N.m). See Figure. Install reverse shaft bolt with Loctite and aluminum washer and torque to 10 ft. lbs. (14 N.m).
  12. Install gear shift and select shaft assembly into left-side case, inserting bottom of gear shift and select shaft into gear shift yoke. Install gear shift interlock bolt and washer into left-side case. Torque to specification. See TORQUE SPECIFICATIONS .
  13. Install back-up light switch into left-side case. Apply silicone sealer to gear shift guide case mating surface. Install gear shift guide case, retaining clamp and secure with 4 bolts. Torque to 89 INCH lbs. (10 N.m). See Fig 9.
  14. 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 10. Torque gear shift shaft 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)
  15. Install gear shift yoke bolt with loctite and torque to 26 ft. lbs. (35 N.m). See Figure. Install left case cap "O" ring and left case cap to left-side case. Torque to 89 INCH lbs. (10 N.m).
  16. Install countershaft LH bearing race to bearing. Select suitable shim to adjust clearance "A". See Fig 11. 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" (.08-.12 mm).
  17. Install left case plate, inserting end in groove of shift guide shaft. See Fig 12. Apply Loctite to screws and torque to 102 INCH lbs. (12 N.m). Ensure countershaft can be rotated by hand.
    Fig 9: Installing Gear Shift Guide Case
    G93J24868Courtesy of GENERAL MOTORS CORP.
    Fig 10: Installing Locating Spring
    G93F24864Courtesy of GENERAL MOTORS CORP.
  18. Install 5th gear to countershaft, facing machined boss inward. Install synchronizer ring springs and 5th speed hub to 5th speed sleeve. Install 5th speed gear shift fork to 5th speed sleeve and hub.
  19. Apply oil to needle bearing. Install 5th gear bearing, input shaft 5th gear, 5th speed synchronizer ring, synchronizer ring spring, 5th speed sleeve, hub and 5th speed gear shift fork onto input shaft as an assembly. Ensure oil grove is aligned with input shaft mark. See Fig 13.
  20. Install gear shift fork spring pin with split side facing away from left-side case. See Figure. Install gear shift guide ball and gear shift fork plug into 5th speed gear shift fork. Install shift fork plug with loctite and torque to 10 ft. lbs. (14 N.m).
  21. Install Lock Nut Wrench (Suzuki 09927-76010) to stop shaft rotation. Install lock nut and torque to 52 ft. lbs. (70 N.m). If lock nut wrench is not available, lock transaxle in 2 gears as outlined in step 1) under TRANSAXLE DISASSEMBLY .
  22. Remove lock nut wrench and stake lock nut. Install 5th speed synchronizer hub plate to input shaft and secure with 5th speed synchronizer retainer. Clean mating surfaces of left-side case and left cover. Apply sealant to left cover mating surface evenly. Install left cover and torque bolts to 53 INCH lbs. (6 N.m).
Fig 11: Selecting Bearing Set Shim
G93G24865Courtesy of GENERAL MOTORS CORP.
Fig 12: Installing Left Case Plate
G93H24866Courtesy of GENERAL MOTORS CORP.
Fig 13: Installing 5th Gear Sleeve & Hub
G93I24867Courtesy of GENERAL MOTORS CORP.
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