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Home >> Suzuki >> 1999 >> Grand Vitara JS+, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - Type "2" 5-Speed >> Transmission Reassembly
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Transmission Reassembly

NOTE: Coat all sliding or rotating parts with gear oil before assembly.
  1. Place intermediate case in vise. Install mainshaft assembly into intermediate case. Install "C" clip onto mainshaft assembly and intermediate case. Align key slots of synchronizer ring and keys, and set input shaft assembly into main shaft assembly. Ensure input shaft turns smoothly. Install "C" clip onto countershaft rear bearing. See Figure .
  2. Install countershaft and rear bearing into intermediate case. Lightly tap out race of bearing with plastic hammer. Install bearing plate. Tighten bolts to 14 ft. lbs. (19 N.m). Install reverse idler gear and shaft. Tighten bolt to 13.5 ft. lbs. (18 N.m).
  3. Install reverse link stay onto intermediate case. Tight bolts to 14 ft. lbs. (19 N.m). Install ball and thrust onto countershaft. Install needle bearing, countershaft 5th gear and synchronizer ring. Align synchronizer ring to sleeve of 5th gear and synchronizer key slot to key.
  4. Press 5th speed synchronizer dog onto countershaft. Select and install circlip that has a maximum thrust clearance of .0039" (.100 mm) or less. See 5TH GEAR CIRCLIP SELECTION  table. Ensure counter 5th gear rotates smoothly. Use a thickness gauge to check counter 5th gear thrust clearance. Standard clearance is .0040-.0118" (.10-.30 mm).
    5TH GEAR CIRCLIP SELECTION

    I.D. Mark Thickness - In. (mm)
    A .1103-.1122 (2.80-2.85)
    B .1122-.1141 (2.85-2.90)
    C .1142-.1161 (2.90-2.95)
    D .1162-.1181 (2.95-3.00)
    E .1182-.1200 (3.00-3.05)
    F .1201-.1240 (3.05-3.10)
    G .1221-.1240 (3.10-3.15)
  5. Install low speed gear shift fork and shaft. Apply thread lock sealer to threads of fork bolt and install. Tighten bolt to 14.5 ft. lbs. (20 N.m). Using a lever and hammer install circlip onto high gear shift shaft. Apply Lithium base grease to locating roller No. 2. and install roller onto low gear shift shaft.
  6. Using a magnet, support locating roller No. 3. Install low gear shift shaft into intermediate case and low shift fork. Apply thread lock sealer to threads of fork bolt and install. Tighten bolt to 14.5 ft. lbs. (20 N.m). Install circlip onto high gear shift shaft. Apply Lithium base grease to locating roller No. 2. and install roller onto reverse gear shift shaft. Assemble reverse gear shift link assembly.
  7. Using a magnet, support locating roller No. 1. Install reverse gear shift shaft into reverse gear shift link assembly and intermediate case. Install reverse gear shift shaft into reverse gear shift link and intermediate case. Install circlip onto low gear shift shaft. Use spring pin remover to insert pin into reverse gear shift link.
  8. Install reverse gear shift yoke and 5th gear shift fork. Use a magnet to support interlock ball. Insert 5th gear shift shaft into 5th gear shift fork and reverse gear shift yoke. Insert 5th gear shift shaft into intermediate case. Apply thread lock sealer to thread of fork bolt and install. Tighten bolt to 14.5 ft. lbs. (20 N.m). Insert 5th-Reverse gear shift shaft into reverse shift yoke using spring pin remover and hammer.
  9. Inspect free length of locating springs. Standard free length for "a" spring should be 1.22" (31.0 mm). Maximum limit is 1.19" (30.1 mm). Standard free length for "b" spring should be .79" (20.2 mm). Maximum limit is .77" (19.6 mm). See Figure . Install locating balls and locating springs. Apply thread lock sealer to thread of locating screw and install. Tighten bolts to 14 ft. lbs. (19 N.m).
  10. Place intermediate case upright on workbench. Evenly apply Suzuki Bond Sealant (1215) or equivalent onto front case side of intermediate case. Install front case onto intermediate case. Install "C" rings onto input shaft bearing and countershaft front bearing. Apply thread lock sealer or equivalent to thread of bolts, input shaft bearing retainer, NEW gasket and install. Tighten bolts to 12.5 ft. lbs. (17 N.m).
  11. Evenly apply Suzuki Bond Sealant (1215) or equivalent onto rear case and rear side of intermediate case. Install rear case onto intermediate case. Install bolts and tighten to 25.5 ft. lbs. (35 N.m).
  12. Hook tip end of gearshift shaft inner lever to head of gear shift shaft. Insert gear shift inner shaft into gear shift shaft inner lever. Apply thread lock sealer to threads of inner gear shift shaft bolt/plug and install. Tighten bolt to 14 ft. lbs. (19 N.m). Tighten plug to 28.5 ft. lbs. (39 N.m).
  13. Install return spring reverse bolt (Black) to left side of case. Install return spring lower bolt to right side of case. Tighten bolts to 20.5 ft. lbs. (28 N.m).
  14. Inspect free length of locating springs. Standard free length for spring should be .87" (22.1 mm). Maximum limit is .83" (21.4 mm). Install locating ball and locating spring to rear case. Apply thread lock sealer to thread of locating screw and install. Tighten bolt to 14 ft. lbs. (19 N.m).
  15. Install NEW casket and backup light switch to rear case. Tighten backup light switch to 32.5 ft. lbs. (45 N.m).
  16. Install clutch housing, release fork and release bearing, onto input shaft. Install and tighten bolts to 61.5 ft. lbs. (85 N.m).
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