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Main Shaft Assembly

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear
  • Use new circlips on shaft for installation. Don't reuse circlips.
  1. Assemble high speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
    1. Slide hub (3) in sleeve (4) so that wider flange side of sleeve (4) and boss side of hub (3) face opposite as shown in the figure, also aligning hub slots with key location teeth of sleeve (4).
    2. Insert keys (2) in hub slots with depression side of keys face center of hub (3).
    3. Install springs (1) to internal circle of key locations with spring end gaps apart at angles about 120 degrees each other, in order to apply spring tension equally to each key.
    NOTE: Do not mix high and low speed synchronizer keys as dimensions are different.
    Fig 1: Assembling High Speed Synchronizer Hub
    G00761950Courtesy of SUZUKI OF AMERICA CORP.
  2. Install synchronizer ring (1) by matching its key slots to keys as shown in the figure.
    Fig 2: Installing Synchronizer Ring
    G00761951Courtesy of SUZUKI OF AMERICA CORP.
  3. Insert 3rd gear (2), needle bearing (3) and high speed sleeve / hub assembly (4) with synchronizer ring to main shaft (1).
    Fig 3: Inserting 3rd Gear
    G00761952Courtesy of SUZUKI OF AMERICA CORP.
  4. Press-fit high speed sleeve / hub assembly (1) with special tool and hydraulic press (2).

    Special tool 

    (A): 09940-53111

    Fig 4: Press-Fitting High Speed Sleeve/Hub Assembly
    G00761953Courtesy of SUZUKI OF AMERICA CORP.
  5. Select circlip (1) that will make thrust clearance of clutch hub 0.1 mm (0.0039 in) or less and install it.
    Fig 5: Circlip Thickness Specifications Chart
    G00761954Courtesy of SUZUKI OF AMERICA CORP.

    Special tool 

    (B): 09900-06107

    Fig 6: Selecting Circlip
    G00761955Courtesy of SUZUKI OF AMERICA CORP.
  6. After installing circlip, check that 3rd gear turns lightly.
  7. Check 3rd gear (2) thrust clearance by using thickness gauge (1). If clearance is out of specification, repress-fit or replace.

    3rd gear thrust clearance 

    0.10 - 0.25 mm (0.004 - 0.010 in.)

    Fig 7: Checking 3rd Gear Thrust Clearance
    G00761956Courtesy of SUZUKI OF AMERICA CORP.
  8. Assemble low speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
    1. Slide hub (3) in sleeve (4) with aligning hub slots with key location teeth of sleeve (4).
    2. Insert keys (2) in hub slots with depression side of keys (2) face center of hub (3).
    3. Install springs (1) to internal circle of key locations with spring end gaps apart at angles about 120 degrees each other, in order to apply spring tension equally to each key.
    NOTE: Before installing hub (3), sleeve (4), springs (1) and keys (2) assembly to main shaft, there is no specific installation direction on each component. However, when installing assembly to main shaft, gear side of sleeve (4) should face to forward direction as shown in the figure.
    Fig 8: Assembling Low Speed Synchronizer Hub
    G00761957Courtesy of SUZUKI OF AMERICA CORP.
  9. Install synchronizer ring (1) by matching its key slots to keys as shown in the figure.
    Fig 9: Installing Synchronizer Ring
    G00761958Courtesy of SUZUKI OF AMERICA CORP.
  10. Insert 2nd gear (2), needle bearing (3) and low speed sleeve / hub assembly (4) with synchronizer ring to main shaft (1).
    Fig 10: Inserting 2nd Gear
    G00761959Courtesy of SUZUKI OF AMERICA CORP.
  11. Press-fit low speed sleeve / hub assembly with special tool and hydraulic press (1).

    Special tool 

    (A): 09940-53111

    Fig 11: Press-Fitting Low Speed Sleeve/Hub Assembly
    G00761960Courtesy of SUZUKI OF AMERICA CORP.
  12. Check 2nd gear thrust clearance referring to Main Shaft Inspection  .
  13. Apply grease to ball (1) and set it to main shaft (3).
  14. Install synchronizer ring (2).
    Fig 12: Installing Synchronizer Ring
    G00761961Courtesy of SUZUKI OF AMERICA CORP.
  15. Install needle bearing (2), low gear (3) and needle bush (1) to main shaft.
    NOTE:
    • Check the cut in needle bush and ball are engaged.
    • After installation, check the synchronizer ring (4) moves in circumferential direction.
    Fig 13: Installing Needle Bearing, Low Gear & Needle Bush To Main Shaft
    G00761962Courtesy of SUZUKI OF AMERICA CORP.
  16. Press-fit main shaft bearing (1) and 5th gear with special tools and hydraulic press (2).
    NOTE: Bring bearing so that its groove for circlip is in the rear.

    Special tool 

    (C): 09940-51710 or (C): 09925-18010

    Fig 14: Press-Fitting Main Shaft Bearing
    G00761963Courtesy of SUZUKI OF AMERICA CORP.
  17. Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it.
    Fig 15: Circlip Thickness Specifications Chart
    G00761964Courtesy of SUZUKI OF AMERICA CORP.
    Fig 16: Selecting Circlip
    G00761965Courtesy of SUZUKI OF AMERICA CORP.
  18. Check low gear clearance referring to Input Shaft Inspection  .
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