Manual Transmission Unit 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 assembly, wash and inspect 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.

Set intermediate case (1) to vise (3).
Clean mating surfaces of intermediate case both sides, if intermediate case is reused.

Fig 1: Setting Intermediate Case To Vise
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Install main shaft assembly (1) to intermediate case.

Fig 2: Installing Main Shaft Assembly To Intermediate Case
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NOTE: When fitting of intermediate case (1) and bearing is tight, tap rear face of intermediate case (1) with plastic hammer lightly as it will cause main shaft assembly (2) to install.

Fig 3: Tapping Rear Face Of Intermediate Case
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Fix with C-ring (1) by using special tool.
Special tool

(A): 09900-06107

Fig 4: Fixing Main Shaft Assembly
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Align key slots of synchronizer ring and synchronizer keys and set input shaft assembly to main shaft assembly. Check that input shaft assembly turns lightly.

Fig 5: Aligning Key Slots Of Synchronizer Ring & Synchronizer Keys
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Install countershaft (1) and rear bearing (2) to intermediate case.
NOTE: When fitting of intermediate case and bearing is tight, tap outer race of bearing lightly and evenly with plastic hammer.

Fig 6: Installing Countershaft & Rear Bearing
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Install bearing plate (1).
Tightening torque

Bearing plate bolt (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 7: Installing bearing plate
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Install reverse idle gear (1) and shaft (2).

Fig 8: Installing Reverse Idle Gear & Shaft
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Tighten reverse gear shift bolt (1) to specification.
Tightening torque

Reverse gear shaft bolt (a): 18 N.m (1.8 Kg-m, 13.0 lb-ft)

Fig 9: Tightening Reverse Gear Shift Bolt
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Install reverse link stay (1).
Tightening torque

Reverse link stay bolt (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 10: Installing Reverse Link Stay
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Set ball (1) and thrust washer (2) to countershaft.

Fig 11: Setting Ball & Thrust Washer To Countershaft
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Install needle bearing (1), countershaft 5th gear (2) and synchronizer ring.
NOTE: When setting synchronizer ring to sleeve of 5th gear, align synchronizer key slot to key.

Fig 12: Installing Needle Bearing
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Press-fit 5th speed synchronizer dog (1) to countershaft with hydraulic press (2) and special tool.
Special tool

(B): 09927-08220

Fig 13: Press-Fitting 5th Speed Synchronizer Dog To Countershaft
Courtesy of SUZUKI OF AMERICA CORP.
Select circlip (1) that will make clearance in circlip groove 0.1 mm (0.0039 in.) or less.

Fig 14: Circlip Thickness Specifications Chart
Courtesy of SUZUKI OF AMERICA CORP.

Fig 15: Measuring Circlip Groove Clearance
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Fix with circlip (1) as shown in the figure and check that counter 5th gear turns lightly.

Fig 16: Fixing Circlip
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Check countershaft 5th gear (1) thrust clearance by using thickness gauge (2). If clearance exceeds limit, repeat Step 1 - 14 again or replace defective part(s).
Countershaft 5th gear thrust clearance

0.1 - 0.3 mm (0.0039 - 0.0118 in.)

Fig 17: Check Countershaft 5th Gear Thrust Clearance
Courtesy of SUZUKI OF AMERICA CORP.
Install low speed gear shift fork, high speed gear shift fork and shaft.
Apply thread lock cement to thread of fork bolt and tighten bolt to specification.
"A": Thread lock cement 99000-32020

Tightening torque

Shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)

Fig 18: Apply Thread Lock Cement To Thread Of Fork Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Fix new circlip (1) to high gear shift shaft by using lever or the like and hammer.

Fig 19: Fixing New Circlip To High Gear Shift Shaft
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Apply grease "A" to locating roller No. 2 (1) and install roller (1) to low gear shift shaft (2).
"A": Grease 99000-25010

Fig 20: Installing Roller To Low Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Supporting locating roller No. 3 (1) by magnet (2), insert low gear shift shaft (3) to intermediate case and low speed gear shift fork.

Fig 21: Inserting Low Gear Shift Shaft To Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Apply thread lock cement "A" to thread of fork bolt and tighten bolt to specification.
"A": Thread lock cement 99000-32020

Tightening torque

Shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)

Fig 22: Tightening Fork Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Fix with new circlip (1) to low gear shift shaft (2) by using lever or the like and hammer.

Fig 23: Installing Low Gear Shift Shaft Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to locating roller No. 2 (1) and install roller No. 2 (1) to reverse gear shift shaft (2).
"A": Grease 99000-25010

Fig 24: Installing Roller No. 2
Courtesy of SUZUKI OF AMERICA CORP.
Assemble reverse gear shift link assembly.
Insert reverse gear shift shaft (2) into reverse gear shift link assembly and intermediate case while holding locating roller No. 1 (1) with magnet (3).
Supporting locating roller No. 1 (1) with magnet (3), insert reverse gear shift shaft (2) into reverse gear shift link and intermediate case.

Fig 25: Inserting Reverse Gear Shift Shaft Into Reverse Gear Shift Link
Courtesy of SUZUKI OF AMERICA CORP.
Fix with new circlip (1) to reverse gear shift shaft by using rod or the like and hammer.

Fig 26: Installing Reverse Gear Shift Shaft Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Drive pin into reverse gear shift link (1) and shaft by using special tool (C).
Special tool

(C): 09922-85811

Fig 27: Driving Pin Into Reverse Gear Shift Link
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse gear shift yoke (1) and 5th gear shift fork (2) as shown in the figure.

Fig 28: Installing Reverse Gear Shift Yoke
Courtesy of SUZUKI OF AMERICA CORP.
Supporting ball (1) with magnet (3) as shown in the figure, insert 5th gear shift shaft (2) to 5th gear shift fork (4) and reverse gear shift yoke (5).

Fig 29: Inserting 5th Gear Shift Shaft To 5th Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Supporting ball (1) with magnet (3) as shown in the figure, insert 5th gear shift shaft (2) into intermediate case (4).

Fig 30: Inserting 5th Gear Shift Shaft Into Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Apply thread lock cement "A" to thread of fork bolt and tighten bolt to specification.
"A": Thread lock cement 99000-32020

Tightening torque

5th gear shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)

Fig 31: Tightening Fork Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Insert 5th-reverse gear shift shaft (1) to reverse gear shift yoke and drive pin into shaft and yoke.
Special tool

(C): 09922-85811

Fig 32: Driving Pin Into Shaft And Yoke
Courtesy of SUZUKI OF AMERICA CORP.
Install locating balls, locating springs and locating screw after checking free length of locating springs.

Fig 33: Locating Springs Free Length Chart
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: For 5th gear locating spring, use shorter spring (1).

"A": Thread lock cement 99000-32020

Tightening torque

Locating spring screw (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 34: Installing Locating Balls, Locating Springs & Locating Screw
Courtesy of SUZUKI OF AMERICA CORP.
Place intermediate case assembly upright as shown in the figure by using workbench or the like.

Fig 35: Placing Intermediate Case Assembly Upright
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Apply sealant evenly to front case side of intermediate case (1) as shown in the figure.
"A": Sealant 99000-31110

Fig 36: Applying Sealant To Front Case Side Of Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of front case (1) and install it to intermediate case.

Fig 37: Installing Front Case To Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Fix C-rings (1, 2) to bearings as shown in the figure.
Special tool

(A): 09900-06107

Fig 38: Fixing C-rings
Courtesy of SUZUKI OF AMERICA CORP.
Apply cement "A" to input shaft bearing retainer bolt and install input shaft bearing (1), new gasket and its bolts.
"A": Thread lock cement 99000-32020

Tightening torque

Input shaft bearing retainer bolt (a): 17 N.m (1.7 kg-m, 12.5 lb-ft)

Fig 39: Tightening Shaft Bearing Retainer Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of rear case and apply sealant evenly to rear case side of intermediate case.
: Sealant 99000-31110
Install rear case to intermediate case.
Tightening torque

Rear case to intermediate case bolt (a): 35 N.m (3.5 kg-m, 25.5 lb-ft)

Fig 40: Installing Rear Case To Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
With tip end of gear shift shaft inner lever (1) hooked on head of gear shift shaft (2), insert gear shift inner shaft (3) into gear shift shaft inner lever.

Fig 41: Inserting Gear Shift Inner Shaft Into Gear Shift Shaft Inner Lever
Courtesy of SUZUKI OF AMERICA CORP.
Apply cement "A" to inner gear shift shaft bolt/plug and tighten them to specification.
"A": Thread lock cement 99000-32020

Tightening torque

Gear shift shaft inner bolt (a): 39 N.m (3.9 kg-m, 28.5 lb-ft)

Gear shift shaft inner plug (b): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 42: Tightening Inner Gear Shift Shaft Bolt/Plug
Courtesy of SUZUKI OF AMERICA CORP.
Tighten return spring low bolt and return spring reverse bolt (black color) (1).
NOTE: Install return spring reverse bolt (black color) (1) to left side of case.

Tightening torque

Return spring reverse bolt (black color) (a): 28 N.m (2.8 kg-m, 20.5 lb-ft)

Fig 43: Tightening Return Spring Low Bolt And Return Spring Reverse Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Apply cement to locating screw (1) and install locating ball (3), locating spring (2) and screw to rear case.
Locating spring free length "a"

Standard: 22.1 mm (0.87 in.)

Limit: 21.4 mm (0.84 in.)

"A": Thread lock cement 99000-32020

Tightening torque

Locating screw (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 44: Installing Locating Ball, Locating Spring & Screw To Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
Install back-up light switch and new gasket.
Tightening torque

Back-up light switch (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)

Fig 45: Installing Back-Up Light Switch
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Install clutch housing (3) and torque its bolts to specification.
Tightening torque

Clutch housing bolt (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 46: Installing Clutch Housing
Courtesy of SUZUKI OF AMERICA CORP.