Manual Transmission Rear Case Disassembly and Assembly: 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.

Check that interlock cam component (1) moves smoothly in both turning direction and sliding direction.

Fig 1: Checking Interlock Cam Component
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Insert interlock cam component (1) to rear case.

Fig 2: Inserting Interlock Cam Component
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Set interlock cam component (1) as shown in the figure and drive pin by using special tool.
Special tool

(A): 09922-85811

Fig 3: Setting Interlock Cam Component
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Apply thread lock cement to thread of interlock cam plug (1) and tighten it to specification.
"A": Thread lock cement 99000-32020

Tightening torque

Interlock cam plug (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 4: Tightening Interlock Cam Plug
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Install oil seal to rear case so that end surface of oil seal becomes flush with that case. Apply grease to oil seal lip.
: Grease 99000-25010

Special tool

(B): 09913-75510

Fig 5: Installing Oil Seal To Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
Install countershaft gutter (2) to transmission rear case (1).

Fig 6: Installing Countershaft Gutter
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