Countershaft Assembly

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Install pin (6), friction gear (5), friction gear spring (4), friction gear retainer (3) and circlip (2) to counter shaft (1) in that order.

Fig 1: Identifying Pin, Friction Gear, Friction Gear Spring & Friction Gear Retainer & Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit front bearing (1) and fit circlip.
Special tool

(A): 09913-84510

Fig 2: Installing Front Bearing
Courtesy of SUZUKI OF AMERICA CORP.
With shaft inserted into case, install center bearing outer race (1) on it and then press-fit counter shaft (2) by using special tool and hammer. Meanwhile case should be supported on wood blocks.
Special tool

(B): 09951-16080

Fig 3: Installing Center Bearing Outer Race & Counter Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit reverse gear (1) and then 5th gear (2).
NOTE: When press-fitting, hold counter shaft (4) as shown in the figure with its front end set on special tool.

Special tool

(C): 09913-80112

(D): 09944-66010

Fig 4: Installing Reverse & 5th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Install bearing plate (1) applying thread lock cement "A" to their thread part of bolts.
"A": Thread lock cement 99000-32020

Tightening torque

Bearing plate bolt (a): 6 N.m (0.6 kg-m, 4.5 lb-ft)

Fig 5: Identifying Bearing Plate & Bearing Plate Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse idle gear (3) together with needle bearing (2) and thrust washer (1) on reverse idle gear shaft (4) and fix them with bolt (5) from outside of case.
NOTE: Be sure to use aluminum washer for bolt.

Tightening torque

Reverse idler gear shaft bolt (b): 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 6: Identifying Reverse Gears & Reverse Gear Components
Courtesy of SUZUKI OF AMERICA CORP.
After press-fitting counter shaft rear bearing (1) to counter shaft, make sure to fit circlip securely.
Special tool

(E): 09913-80112

Fig 7: Installing Counter Shaft Rear Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Fit circlip (1) around bearing (2) and check to make sure that circlip just contacts with case surface.

Fig 8: Identifying Circlip & Bearing
Courtesy of SUZUKI OF AMERICA CORP.