Manual Transmission Unit Assembly

NOTE:

Before assembly, wash and inspect each part and apply specified gear oil to sliding faces of bearing and gear.
Use new circlips on shaft for installation. DO NOT reuse circlips.

Set intermediate case (1) to vise (3).
Clean mating surfaces of intermediate case both sides, if intermediate case is reused.

Fig 1: Setting Intermediate Case To Vise
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Install main shaft assembly (1) to intermediate case.

Fig 2: Installing Main Shaft Assembly To Intermediate Case
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NOTE: When fitting of intermediate case (1) and bearing is tight, tap rear face of intermediate case (1) with plastic hammer lightly as it will cause main shaft assembly (2) to install.

Fig 3: Tapping Rear Face Of Intermediate Case
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Fix bearing with new C-ring (1) using special tool.
Special tool
1. (A): 09900-06107
Fig 4: Fixing Bearing With C-Ring
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Align key slots of high speed synchronizer hub (1) and protrusion of 4th gear synchronizer ring (2) and set input shaft assembly to main shaft assembly.
Check that input shaft assembly turns lightly.

Fig 5: Aligning Key Slots Of High Speed Synchronizer Hub
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Fix with new C-ring to countershaft rear bearing.
Install countershaft (1) and rear bearing (2) to intermediate case (3).
NOTE:
- When installing rear bearing (2), bring it so that its C-ring side is at rear side of intermediate case as shown in the figure.
- When fitting of intermediate case (3) and rear bearing (2) is tight, tap outer race of rear bearing (2) lightly and evenly with plastic hammer.
Fig 6: Installing Countershaft & Rear Bearing
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Install reverse idle gear (1) and shaft (2).

Fig 7: Installing Reverse Idle Gear & Shaft
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Install main shaft and countershaft bearing plate (1) to intermediate case.
Tightening torque
1. Main and countershaft bearing plate bolt (a): 18 N.m (1.8 kg-m, 13.0 lb-ft)
Fig 8: Installing Main Shaft & Countershaft Bearing Plate To Intermediate Case
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Set pin (1) and thrust washer (2) to countershaft.

Fig 9: Setting Pin & Thrust Washer To Countershaft
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Assemble countershaft 5th gear (1), plate spring (2), circlip (3), 5th and reverse synchronizer sleeve (4), balk levers (5), synchronizer key spring (6) and 5th and reverse synchronizer ring (7) according to the following procedure.

Fig 10: Assembling Countershaft 5th Gear
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1. Install plate spring (1) to countershaft 5th gear (3) and fix plate spring (1) with new circlip (2) using special tool.
  Special tool
  1. (A): 09900-06107
  Fig 11: Installing Plate Spring To Countershaft 5th Gear & Fixing Plate Spring
  Courtesy of SUZUKI OF AMERICA CORP.
2. Install 5th and reverse synchronizer sleeve (1) to countershaft 5th gear (2) in specified direction as shown in the figure.
  
  Fig 12: Installing 5th & Reverse Synchronizer Sleeve To Countershaft 5th Gear
  Courtesy of SUZUKI OF AMERICA CORP.
3. Fit balk levers (1) to countershaft 5th gear (2) in specified direction as shown in the figure.
  
  Fig 13: Fitting Balk Levers To Countershaft 5th Gear
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4. Install synchronizer key spring (1).
  
  Fig 14: Installing Synchronizer Key Spring
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5. Slide 5th and reverse synchronizer sleeve (1) until sliding surface of balk lever is locked into key location teeth of 5th and reverse synchronizer sleeve (1) with balk lever and synchronizer key spring pushed.
  
  Fig 15: Sliding 5th & Reverse Synchronizer Sleeve
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6. Install synchronizer ring (1) to countershaft 5th gear (4).
  NOTE: Align protrusions (2) of synchronizer ring (1) with groove (3) of countershaft 5th gear (4).
  
  Fig 16: Installing Synchronizer Ring To Countershaft 5th Gear
  Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing (1) into countershaft 5th gear assembly (2) which was assembled in Steps a) to f).
Install countershaft 5th gear assembly (2) to countershaft (3) facing gear side to intermediate plate (4).

Fig 17: Installing Countershaft 5th Gear Assembly To Countershaft
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Press-fit 5th speed synchronizer dog (1) to countershaft with hydraulic press (2) and special tool.
Special tool
1. (B): 09913-84510
Fig 18: Press-Fitting 5th Speed Synchronizer Dog To Countershaft
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Select circlip (1) that will make clearance in circlip groove 0.1 mm (0.0039 in.) or less.

Fig 19: Circlip Thickness Specifications Table
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Fig 20: Measuring Circlip Thickness
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Fix with circlip (1) as shown in the figure and check that countershaft 5th gear (2) turns lightly.

Fig 21: Fixing Countershaft 5th Gear With Circlip
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Check countershaft 5th gear (1) thrust clearance using thickness gauge (2).
If clearance exceeds limit, repeat Step 1 to 15 again or replace defective part(s).
1. Countershaft 5th gear thrust clearance: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
Fig 22: Checking Countershaft 5th Gear Thrust Clearance
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Install reverse gear shift arm bracket (1) to intermediate case (2).
Tightening torque
1. Reverse gear shift arm bracket bolt (a): 18 N.m (1.8 kg-m, 13.0 lb-ft)
Fig 23: Installing Reverse Gear Shift Arm Bracket To Intermediate Case
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Install reverse gear shift arm (1) to reverse gear shift fork (2) fixing it with new circlip (3), if necessary.

Fig 24: Installing Reverse Gear Shift Arm To Reverse Gear Shift Fork
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Fit reverse gear shift arm/fork (1) to reverse idle gear and then install reverse gear shift arm/fork (1) to reverse gear shift arm bracket (2).
Insert spring (3) and ball (4) to reverse gear shift fork (5) using magnet.

Fig 25: Inserting Spring & Ball To Reverse Gear Shift Fork
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Insert 5th and reverse guide shaft (1) to reverse gear shift fork (3) and intermediate case (4) from front side pushing ball (5) by rod (2).
CAUTION: Be sure to install 5th and reverse guide shaft as specified direction. If failure to follow above-mentioned procedure, 5th and reverse guide shaft could result in wrong assembly which ball (5) Installed to (6) hole for interlock pin.

Fig 26: Inserting 5th & Reverse Guide Shaft To Reverse Gear Shift Fork
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Insert ball (1) to reverse gear shift fork (2) and interlock pin (3) to intermediate case (4) using magnet.

Fig 27: Inserting Ball To Reverse Gear Shift Fork & Interlock Pin To Intermediate Case
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Install 5th gear shaft (2) after fitting 5th gear shift fork (1) to 5th and reverse synchronizer sleeve (3).

Fig 28: Installing 5th Gear Shaft
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Drive spring pin (1) into 5th gear shift fork (2) and shaft (3) up to 5th gear shift fork (2) surface using plastic hammer.

Fig 29: Driving Spring Pin Into 5th Gear Shift Fork
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Install new circlips (1) to groove of 5th gear shift shaft (2), and 5th and reverse guide shaft (3) using lever (4) or the like and hammer.

Fig 30: Installing Circlips To Groove Of 5th Gear Shift Shaft
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Insert interlock pin (1) to intermediate case (2) using magnet (3).

Fig 31: Inserting Interlock Pin To Intermediate Case
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Apply grease to straight pin (1) and install straight pin (1) to low speed gear shift shaft (2).
1. "A": Grease 99000-25010
Fig 32: Installing Straight Pin To Low Speed Gear Shift Shaft
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Install low speed gear shift fork (1) and low speed gear shift shaft (2).

Fig 33: Installing Low Speed Gear Shift Fork & Shaft
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Insert interlock pin (1) to intermediate case (2) using magnet (3).

Fig 34: Inserting Interlock Pin To Intermediate Case
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Install high speed gear shift fork (1) and high speed gear shift shaft (2).

Fig 35: Installing High Speed Gear Shift Fork & Shaft
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Install new circlips (1) to high speed gear shift shaft (2) and low speed gear shift shaft (3) using lever (4) or the like and hammer.

Fig 36: Installing Circlips To High Speed Gear Shift Shaft
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Install new low speed gear shift fork bolt (1) and high speed gear shift fork bolt (2) and tighten bolts to specified torque.
Tightening torque
1. Low and high speed gear shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)
Fig 37: Installing Low & High Speed Gear Shift Fork Bolt
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Install locating balls (1), locating springs (2) and new locating screws (3).
Tightening torque
1. Locating screw (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)
Fig 38: Installing Locating Balls, Springs & Screws
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Place intermediate case assembly (1) upright as shown in the figure using workbench (2) or the like.

Fig 39: Placing Intermediate Case Assembly Upright
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Apply sealant evenly to front case side of intermediate case (1) as shown in the figure.
1. "A": Sealant 99000-31110
Fig 40: Applying Sealant To Front Case Side Of Intermediate Case
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Clean mating surface of front case (1) and install it to intermediate case.

Fig 41: Installing Front Case To Intermediate Case
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Fix new C-rings (1, 2) to bearings as shown in the figure.
Special tool
1. (A): 09900-06107
Fig 42: Fixing C-Rings To Bearings
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Clean mating surface of input shaft bearing retainer (1) and apply sealant evenly to input shaft bearing retainer (1).
1. "B": Sealant 99000-31110
Fig 43: Applying Sealant To Input Shaft Bearing Retainer
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Install input shaft bearing retainer (1) tightening new input shaft bearing plate bolt to specified torque.
Tightening torque
1. Input shaft bearing retainer bolt (a): 17 N.m (1.7 kg-m, 12.5 lb-ft)
Fig 44: Installing Input Shaft Bearing Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Insert gear shift inner shaft (1) and gear shift inner lever (2) to rear case (4).
Drive spring pin (3) into gear shift inner lever (2) using special tool.
Special tool
1. (A): 09922-85811
Fig 45: Driving Spring Pin Into Gear Shift Inner Lever
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of rear case (1) and apply sealant evenly to rear case side of intermediate case (2).
1. "A": Sealant 99000-31110
Fig 46: Applying Sealant To Rear Case Side Of Intermediate Case
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Install rear case (1) to intermediate case (2) with tip end of gear shift shaft inner lever (3) hooked on head of gear shift shaft (4).
Tighten case bolts to specified torque.

Tightening torque
1. Rear case to intermediate case bolt (a): 37 N.m (3.7 kg-m, 27.0 lb-ft)
Fig 47: Installing Rear Case To Intermediate Case
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Tighten return spring low bolt (2) and return spring reverse bolt (black color) (1).
NOTE: Install return spring reverse bolt (black color) (1) to left side of case.

Tightening torque
1. Return spring reverse bolt (black color) (a): 37 N.m (3.7 kg-m, 27.0 lb-ft)
2. Return spring low bolt (b): 37 N.m (3.7 kg-m, 27.0 lb-ft)
Fig 48: Installing Return Spring Reverse Bolt To Left Side Of Case
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Install back-up light switch with new gasket.
Tightening torque
1. Back-up light switch (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)
Fig 49: Installing Back-Up Light Switch
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Install clutch housing (3) and torque its bolts to specification.
NOTE: Use new two mounting bolts (1) as shown in the figure.

Tightening torque
1. Clutch housing bolt (a): 36 N.m (3.6 kg-m, 26.0 lb-ft)
Install clutch release fork (2) and release bearing (4).

Fig 50: Installing Clutch Release Fork & Release Bearing
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