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Manual Transmission Rear Case Disassembly and Assembly: Assembly

  1. Check that interlock cam component (1) moves smoothly in both turning direction and sliding direction.
    Fig 1: Checking Interlock Cam Component
    G01326067Courtesy of SUZUKI OF AMERICA CORP.
  2. Insert interlock cam component (1) to rear case.
    Fig 2: Inserting Interlock Cam Component
    G01326068Courtesy of SUZUKI OF AMERICA CORP.
  3. Set interlock cam component (1) as shown in the figure and drive pin by using special tool.

    Special tool 

    1. (A):  09922-85811
    Fig 3: Setting Interlock Cam Component
    G01326069Courtesy of SUZUKI OF AMERICA CORP.
  4. Apply thread lock cement to thread of interlock cam plug (1) and tighten it to specification.

    "A":  Thread lock cement 99000-32020

    Tightening torque 

    1. Interlock cam plug (a):  19 N.m (1.9 kg-m, 14.0 lb-ft)
    Fig 4: Tightening Interlock Cam Plug
    G01326070Courtesy of SUZUKI OF AMERICA CORP.
  5. 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 

    1. (B):  09913-75510
    Fig 5: Installing Oil Seal
    G01326071Courtesy of SUZUKI OF AMERICA CORP.
  6. Install countershaft gutter (2) to transmission rear case (1).
    Fig 6: Installing Countershaft Gutter
    G01326072Courtesy of SUZUKI OF AMERICA CORP.