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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 Movement
    G01326260Courtesy of SUZUKI OF AMERICA CORP.
  2. Insert interlock cam component (1) to rear case.
    Fig 2: Inserting Interlock Cam Component To Rear Case
    G01326261Courtesy of SUZUKI OF AMERICA CORP.
  3. Set interlock cam component (1) as shown in the figure and drive interlock cam pin (2) using special tool.

    Special tool 

    1. (A):  09922-85811
    Fig 3: Setting Interlock Cam Component
    G01326262Courtesy of SUZUKI OF AMERICA CORP.
  4. Install new interlock cam plug (1) and tighten it to specification.

    Tightening torque 

    1. Interlock cam plug (a):  19 N.m (1.9 kg-m, 14.0 lb-ft)
    Fig 4: Installing New Interlock Cam Plug
    G01326263Courtesy of SUZUKI OF AMERICA CORP.
  5. Install new 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 To Rear Case
    G01326264Courtesy of SUZUKI OF AMERICA CORP.
  6. Install countershaft gutter (2) to transmission rear case (1).
    Fig 6: Installing Countershaft Gutter To Transmission Rear Case
    G01326265Courtesy of SUZUKI OF AMERICA CORP.