Manual Transaxle Assembly Disassembly and Assembly: Assembly

Join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft (3) assemblies all together, then install them into right case (1) so as not to damage oil seal by input shaft spline.
NOTE:
- Input shaft right bearing on shaft can be installed into right case by tapping shaft with plastic hammer.
- Make sure that countershaft is engaged with final gear while installing.
Fig 1: Installing Input Shaft, Countershaft, Low Speed Gear Shift Shaft And High Speed Gear Shift Shaft Assemblies
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Install 5th & reverse gear shift shaft (1) with 5th & reverse gear shift guide shaft (2) into right case (5). Reverse gear shift arm (4) has to be joined with reverse gear shift lever (3) at the same time.

Fig 2: Installing 5th & Reverse Gear Shift Shaft With 5th & Reverse Gear Shift Guide Shaft
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Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) into case (4) through idler gear and then align "A" in shaft with "B" in case.
NOTE:
- Make sure that washer (5) has been installed in shaft at above the gear.
- Confirm that reverse gear shift lever end has clearance 0.5 - 1 mm (0.02 - 0.04 in.) to idler gear groove.
Fig 3: Inserting Reverse Gear Shaft Into Case & Checking Clearance
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Tighten reverse gear shift lever, bolts after applying thread lock cement.
: Thread lock cement 99000-32110

Tightening torque

Reverse gear shift lever bolt: 23 N.m (2.3 kg-m, 17.0 lb-ft)
Install differential assembly into right case.
Clean mating surfaces of both right and left cases, and apply sealant to right case (2) as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter then mate it with left case (1).
"B": Sealant 99000-31260
Tighten case bolts (3) from outside to specified torque.
Tightening torque

Transaxle case bolt (b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
Install reverse shaft bolt (4), to which thread lock cement has been applied, with aluminum washer and tighten it.
"A": Thread lock cement 99000-32110

Tightening torque

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

Fig 4: Installing Right Case
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Install another case bolts from clutch housing side and tighten them to specification.
Tightening torque

Transaxle case bolt: 23 N.m (2.3 kg-m, 17.0 lb-ft)
Install differential side bearing outer race to left case, and tap and accustom outer race using special tool and plastic hammer.
CAUTION: : Do not drive in a race with hammer. Driving it way cause to damage bearing.

Special tool

(A): 09926-27610

Fig 5: Installing Differential Side Bearing Outer Race
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Select a shim of differential side bearing as follows.
1. Measure depth "a" from left case end face (1) to side bearing outer race (2) using depth gauge.
  
  Fig 6: Measuring Depth "a" From Left Case End Face To Side Bearing Outer Race
  Courtesy of SUZUKI OF AMERICA CORP.
2. Measure height "b" of side bearing retainer with depth gauge.
  
  Fig 7: Measuring Height "b" Of Side Bearing Retainer
  Courtesy of SUZUKI OF AMERICA CORP.
3. Calculate clearance "a" - "b", and select a shim according to the following table.
  
  Fig 8: Bearing Shim Table
  Courtesy of SUZUKI OF AMERICA CORP.
Install differential side bearing shim to left case (3).
Apply oil to new O-ring of side bearing retainer (2), and then install side bearing retainer with O-ring to left case (3).
Tighten side bearing retainer bolts (1) to specified torque.
NOTE:
- Install side bearing retainer with its punch mark (4) facing upward
Tightening torque

Side bearing retainer bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 9: Installing Side Bearing Retainer
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Check locating springs for deterioration and replace with new ones as necessary.

Fig 10: Locating Spring Free Length Table
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Install steel ball (3) and locating spring for respective gear shift shaft and tighten with bolt (1) to which sealant has been applied.
"A": Sealant 99000-31260

Tightening torque

Gear shift locating bolt (a): 13 N.m (1.3 kg-m, 9.5 lb-ft)

Fig 11: Installing Steel Balls And Locating Springs
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To seat countershaft left bearing outer race (2) to bearing cone, tap cup by using special tool and plastic hammer.
Special tool

(A): 09913-70123

Fig 12: Seating Countershaft Left Bearing Outer Race
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Put a shim (3) on bearing outer race (4) provisionally, place straight edge (1) over it and compress it by hand through straight edge, and then measure "a" (Clearance between case surface (5) and straight edge) by using feeler gauge (6).
Clearance between case surface and straight edge

"a": 0.08 - 0.12 mm (0.0032 - 0.0047 in.)
By repeating step 2), select a suitable shim which adjusts clearance "a" to specification and put it on bearing outer race.
NOTE: Insert 0.1 mm (0.004 in.) feeler to know whether or not a shim fulfills specification quickly.

Fig 13: Available Countershaft 5th Gear Shim Thickness Table
Courtesy of SUZUKI OF AMERICA CORP.

Fig 14: Selecting Suitable Shim
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Place left case plate (2) inserting its end in groove of shift guide shaft (4) and then tighten bolts (1) to which thread lock cement has been applied.
NOTE: After tightening bolts, make sure that countershaft can be rotated by hand feeling certain load.

"A": Thread lock cement 99000-32110

Tightening torque

Left case plate bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 15: Installing Left Case Plate
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