Manual Transmission Rear Case Disassembly & Assembly: Assembly

WARNING: This page is about a different car, the 2004 Suzuki XL-7. 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 Movement
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Insert interlock cam component (1) to rear case (2).

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

(A): 09922-85811

Fig 3: Setting Interlock Cam Component
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Install new interlock cam plug (1) and tighten it to specification.
Tightening torque

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

Fig 4: Installing New Interlock Cam Plug
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Install new 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
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Install countershaft gutter (2) to transmission rear case (1).

Fig 6: Installing Countershaft Gutter To Transmission Rear Case
Courtesy of SUZUKI OF AMERICA CORP.