Manual Transmission Unit Assembly

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

Put main shaft-input shaft assembly (7) into lower case (6), apply oil to component parts and check for proper engagement (smooth rotation) with counter shaft.
NOTE: For vehicle equipped with scissors gears, align paint match marks (1) marked before disassembly as shown in the figure when installing main shaft to lower case (6).
After cleaning mating surfaces of both cases, coat mating surface of upper case (8) with sealant evenly and put it over lower case (6). At this time, all gears and forks should be set to neutral position.
"A": Sealant 99000-31150

Fig 1: Identifying Scissors Gears
Courtesy of SUZUKI OF AMERICA CORP.
Place bolts at their position and check to make sure that their height from case surface is the same before tightening them. Also, check clamp position and torque them to specification.
Tightening torque

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

Fig 2: Identifying Bolt Height, (From Case Surface)
Courtesy of SUZUKI OF AMERICA CORP.
Apply sealant "A" to mating surface of input shaft bearing retainer (1) and its bolts (2), then install them.
"A": Sealant 99000-31110

Tightening torque

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

Fig 3: Applying Sealant To Mating Surface Of Input Shaft Bearing Retainer & Bearing Retainer Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install clutch housing (1) and torque its bolts (2) to specification.
Tightening torque

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

Fig 4: Identifying Clutch Housing & Clutch Housing Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install release bearing
Clean mating surfaces of both cases, coat mating surface (1) of rear case with sealant evenly and mate it with transmission itself.
"A": Sealant 99000-31110

Fig 5: Identifying Transmission & Rear Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
Install 12 rear case bolts and torque them to specification.
Tightening torque

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

Fig 6: Identifying Rear Transmission Case Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install back up light switch (1).
Tightening torque

Back up light switch (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)
Install gear shift lever case (4) temporarily to confirm switch function by checking the following.
- Back up light switch (1) should conduct when gear shift control lever (3) is at reverse position.
  
  Fig 7: Checking Back Up Light Switch Continuity
  Courtesy of SUZUKI OF AMERICA CORP.
After confirming switch function, remove gear shift lever case.
Connect transfer assembly to transmission and tighten its fastening bolts to specified torque.
Tightening torque

Transfer to transmission bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
With sealant applied to mating surface of transmission gear shift lever case assembly (5), put it onto transmission and transfer assembly, and torque bolts to specification.
"A": Sealant 99000-31110

Tightening torque

Gear shift case bolt (b): 13 N.m (1.3 kg-m, 9.5 lb-ft)
Install breather hoses (4) for transmission and transfer and set clamps.
Connect wiring harness (3) to each coupler of 4WD switch, 5th switch and back up light switch.
Clamp wiring harness (3) and breather hoses (4) securely.
CAUTION: Fill specified amount of gear oil to transmission and transfer after remounting transmission and transfer assembly to vehicle.

Fig 8: Identifying Transmission & Transfer Assembly With Exterior Components
Courtesy of SUZUKI OF AMERICA CORP.