Gear Shift Lever Case (4WD Model) Disassembly & Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

Wash and inspect each part and replace if necessary. Also check items as described below and correct whatever necessary carefully by using reamer, oilstone and the like, wash it thoroughly and reassemble them.
Items to be checked are:
- Shift shaft should go into case smoothly.
- Shift lever, limit yoke and shift arm should go into shift shaft smoothly.
Insert shift shaft (1) as shown while making sure that inner parts are in proper direction.
NOTE:
- Cut off portion (5) in shift should face downward when shift shaft (1) is installed.
- Use care for installing direction of shift limit spring (4).
- Shift arm should be installed at the same time.
  
  Fig 1: Identifying Gear Shift Lever Case & First Set Of Components To Be Assembled (4WD Model)
  Courtesy of SUZUKI OF AMERICA CORP.
Drive in spring pin (single short) for reverse gear shift limit yoke.
Drive in spring pin (double) for shift lever.
Drive in spring pin (single long) for return spring.
Fit straight end of shift limit spring (2) into line groove in shift limit yoke (1) and with its other hooked end turned in its winding direction by about 90° from its free state, hook it on spring pin (4).

Fig 2: Identifying Gear Shift Lever Case & Second Set Of Components To Be Assembled (4WD Model)
Courtesy of SUZUKI OF AMERICA CORP.
Drive in spring pin for shift arm.
Press-fit case plug (1) into case.

Fig 3: Identifying Caulking Points & Case Plug (4WD Model)
Courtesy of SUZUKI OF AMERICA CORP.
After applying grease "A", install select guide pins, select return springs and spring bolts (2) and torque them to specification.
"A": Grease 99000-25010

Tightening torque

Select return spring bolt (for 4WD model) (a): 35 N.m (3.5 kg-m, 25.5 lb-ft)

NOTE: Double coil spring is required at 5th / Reverse select side.
Clean mating surfaces of both case plate and case, apply sealant "B" to case side evenly, mate them and fasten with screws (5).
"B": Sealant 99000-31110

Tightening torque

Shift lever case plate screw (b): 9 N.m (0.9 kg-m, 6.5 lb-ft)
If reverse gear shift limit bolt (1) has been removed, apply thread lock cement "C" to bolt then install and torque it to specification.
"C": Thread lock cement 99000-32020

Tightening torque

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

Fig 4: Identifying Select Return Springs, Bolts & Reverse Gear Shift Limit Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Install gear shift lever case (2) to transmission without using sealant for functional check.
Install shift control lever and check to make sure that it shifts smoothly according to shift pattern.
NOTE:
- Apply thread lock cement "C" to control lever locating bolts (1) when replaced.
- Be sure to apply sealant to mating surface of gear shift lever for its final installation.
"C": Thread lock cement 99000-32020

Tightening torque

Transmission control lever locating bolt (d): 17 N.m (1.7 kg-m, 12.5 lb-ft)

Fig 5: Identifying Thread Lock Application Areas

Courtesy of SUZUKI OF AMERICA CORP.