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Transaxle Reassembly

  1. Using seal installer, install left differential oil seal in left side case. Apply transmission assembly lubricant to seal lips. Apply Loctite to oil gutter bolt and install oil gutter and bolt. Tighten bolt to 9 ft. lbs. (12 N.m). Using seal installer, install gearshift shaft oil seal into right side case. Apply transmission assembly lubricant to seal lips. Install gear shift shaft boot onto gearshift shaft. Ensure vent opening in boot faces down. Install gearshift shaft through shaft seal and into right side case.
  2. Drive in NEW differential oil seal into right side case. Install steel ball and gearshift shaft spring into case. Apply Loctite to gearshift shaft bolt and install bolt and washer. Tighten to 10 ft. lbs. (13 N.m). Apply Loctite to gearshift arm bolt. Install gearshift arm onto shift shaft and tighten arm bolt to 26 ft. lbs. (36 N.m). Install magnet into right side case.
  3. Install countershaft right-side bearing race. See Fig 1. Install 5th-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 1. Tighten bolts to 17 ft. lbs. (23 N.m). Install input shaft oil seal with spring side upward.
  4. Apply grease to input shaft oil seal lip and speedometer driven gear case "O" ring. Install speedometer driven gear case into right side case. Install driven gear case retaining bolt and tighten to 53 INCH lbs. (6 N.m).
  5. Assemble input shaft and countershaft together with high and low speed gear shift shaft assemblies. Install into right-side case. See Fig 2.
  6. Ensure countershaft is engaged to final gear. Install differential assembly flush into right-side case. Rotate differential assembly to ensure speedometer drive gear meshes with speedometer driven gear.
    Fig 1: Installing Reverse Gear Shift Lever
    G93C24861Courtesy of GENERAL MOTORS CORP.
    Fig 2: Installing Input Shaft & Countershaft
    G93D24862Courtesy of GENERAL MOTORS CORP.
    Fig 3: Installing & Aligning Reverse Gear Shaft
    G93E24863Courtesy of GENERAL MOTORS CORP.
  7. Install 5th-reverse gear shift shaft with 5th-reverse gear shift guide shaft into right-side case. See Figure. Join reverse gear shift arm to reverse gear shift lever.
  8. 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 3. Install gear shift yoke to gear shift arm. Clean mating surfaces of left and right-side cases.
  9. 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 tighten to 16 ft. lbs. (22 N.m). See Figure. Install reverse shaft bolt with Loctite and aluminum washer and tighten to 10 ft. lbs. (14 N.m).
  10. 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. Tighten to specification. See TORQUE SPECIFICATIONS .
  11. 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. Tighten to 89 INCH lbs. (10 N.m).
  12. Inspect shift shaft detent springs for deterioration or deformation. See SHIFT SHAFT DETENT SPRING SPECIFICATIONS  table. Replace with new springs as necessary. Install steel balls, spring, washers and bolts. See Fig 4. Tighten gear shift shaft bolts to 10 ft. lbs. (14 N.m).
    SHIFT SHAFT DETENT SPRING SPECIFICATIONS

    Spring Application Length - In. (mm)
    Esteem
    High Speed Spring
    Standard Length 1.535 (39.00)
    Service Limit 1.579 (44.00)
    Low Speed Spring
    Standard Length 1.028 (26.10)
    Service Limit .984 (25.00)
    5th-Reverse Spring
    Standard Length 1.028 (26.10)
    Service Limit .984 (25.00)
    Metro & Firefly (Canadian)
    High Speed Spring
    Standard Length 1.597 (40.10)
    Service Limit 1.535 (39.00)
    Low Speed Spring
    Standard Length 1.028 (26.10)
    Service Limit .984 (25.00)
    5th-Reverse Spring
    Standard Length 1.028 (26.10)
    Service Limit .984 (25.00)
    Swift
    High Speed Spring (Purple)
    Standard Length 1.579 (40.10)
    Service Limit 1.535 (39.00)
    Low Speed Spring (Purple)
    Standard Length 1.028 (26.10)
    Service Limit .984 (25.00)
    5th-Reverse Spring (Purple)
    Standard Length 1.028 (26.10)
    Service Limit .984 (25.00)
  13. Install gear shift yoke bolt with loctite and tighten to 26 ft. lbs. (35 N.m). See Figure. Install left case cap "O" ring and left case cap to left-side case. Tighten to 89 INCH lbs. (10 N.m).
  14. Install countershaft left-side bearing race to bearing. Select suitable shim to adjust clearance "A". See Fig 5. 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).
  15. Install left case plate, inserting end in groove of shift guide shaft. See Fig 6. Apply Loctite to screws and tighten to 89 INCH lbs. (10 N.m). Ensure countershaft can be rotated by hand.
    Fig 4: Installing Locating Springs
    G93F24864Courtesy of GENERAL MOTORS CORP.
  16. Install 5th gear to countershaft, with machined boss facing 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.
  17. 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 groove is aligned with input shaft mark. See Fig 7.
  18. 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 tighten to 10 ft. lbs. (14 N.m).
  19. Install Lock Nut Wrench (Suzuki 09927-76010) to stop shaft rotation. Install lock nut and tighten 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.
  20. 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 tighten bolts to 53 INCH lbs. (6 N.m).
Fig 5: Selecting Bearing Set Shim
G93G24865Courtesy of GENERAL MOTORS CORP.
Fig 6: Installing Left Case Plate
G93H24866Courtesy of GENERAL MOTORS CORP.
Fig 7: Installing 5th Gear Sleeve & Hub
G93I24867Courtesy of GENERAL MOTORS CORP.
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