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Home >> Suzuki >> 2004 >> Forenza S, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - M/T >> Repair Instructions >> Major Component Assy Assembly >> Assembly
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Major Component Assy Assembly: Assembly

  1. Join the mainshaft and the input shaft.
  2. Compress the snap ring at the base of the mainshaft and hold with the snap ring retainer J-36633.
  3. Hold the snap ring at the base of the input driveshaft with the snap ring pliers.
  4. Install the mainshaft/input shaft assembly onto the bearing plate.
  5. Release the mainshaft snap ring and the input shaft snap ring.
    Fig 1: Releasing The Mainshaft Snap Ring
    G00785660Courtesy of SUZUKI OF AMERICA CORP.
  6. Position the first-second gearshift fork.
  7. Install the fifth gearshift lever into the bearing plate.
    Fig 2: Installing The Fifth Gearshift Lever
    G00785661Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the third-fourth gearshift rod/fork holding pin.
    Fig 3: Installing The Third-Fourth Gearshift Rod/Fork Holding Pin
    G00785662Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the support bracket onto the bearing plate.
    Fig 4: Installing The Support Bracket
    G00785663Courtesy of SUZUKI OF AMERICA CORP.
  10. Install the first-second gearshift rod/fork onto the bearing plate.
    Fig 5: Installing The First-Second Gearshift Rod/Fork
    G00785664Courtesy of SUZUKI OF AMERICA CORP.
  11. Install the first-second gearshift fork holding pin.
    Fig 6: Installing The First-Second Gearshift Fork Fork Holding Pin
    G00785665Courtesy of SUZUKI OF AMERICA CORP.
  12. Install the support bracket bolts.

    Tighten 

    Tighten the support bracket bolts to 7 N.m (62 lb-in).

    Fig 7: Installing The Support Bracket
    G00785666Courtesy of SUZUKI OF AMERICA CORP.
  13. Install the reverse gearshift rod/fork onto the bearing plate.
    Fig 8: Installing The Reverse Gearshift Rod/Fork
    G00785667Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the reverse gearshift rod/fork holding pin.
    Fig 9: Installing The Reverse Gearshift Rod/Fork Holding Pin
    G00785668Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the rod lock pin and spring into the small plug hole.
    Fig 10: Installing The Rod Lock Pin
    G00785669Courtesy of SUZUKI OF AMERICA CORP.
  16. Install the fourth-gearshift rod plugs.
    Fig 11: Installing The Fourth-Gearshift Rod Plugs
    G00785670Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the bolts and the fifth-gearshift connector onto the bearing plate, using the pawl.

    Tighten 

    Tighten the fifth-gearshift connector bolts to 7 N.m (62 lb-in).

    Fig 12: Install The Bolts & Fifth-Gearshift Connector
    G00785671Courtesy of SUZUKI OF AMERICA CORP.
  18. Install the input drive fifth gear using the installer KM-554 and the installer sleeve KM-334.
    Fig 13: Installing The Input Drive Fifth Gear
    G00785672Courtesy of SUZUKI OF AMERICA CORP.
  19. Install the snap rings securing the fifth-drive gear.
    Fig 14: Installing The Snap Rings
    G00785673Courtesy of SUZUKI OF AMERICA CORP.
  20. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven fifth-gear assembly.
    Fig 15: Installing Thrust Washers
    G00785674Courtesy of SUZUKI OF AMERICA CORP.
  21. Install the brass synchronizer ring onto the mainshaft-driven fifth-gear assembly.
    Fig 16: Installing The Brass Synchronizer Ring
    G00785675Courtesy of SUZUKI OF AMERICA CORP.
  22. Install the mainshaft-driven fifth-gear assembly.
  23. Install the fifth-drive gear synchronizer gear and the synchronizer sleeve using installer KM-554.
    Fig 17: Installing The Fifth-Drive Gear Synchronizer Gear
    G00785676Courtesy of SUZUKI OF AMERICA CORP.
  24. Install the snap ring holding the fifth speed-driven assembly.
    Fig 18: Installing The Snap Ring
    G00785677Courtesy of SUZUKI OF AMERICA CORP.
  25. Install the bolts and the fifth-gear fork onto the bearing plate.

    Tighten 

    Tighten the fifth-gear fork bolts to 22 N.m (16 lb-ft).

    Fig 19: Installing The Bolts & Fifth-Gear Fork
    G00785678Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove the bearing plate from the fixture KM-552.
  27. Shift the transaxle into second gear.
  28. Install the bearing plate, with the shafts attached, into the case.
    Fig 20: Installing The Bearing Plate
    G00785679Courtesy of SUZUKI OF AMERICA CORP.
  29. Install the bearing plate bolts.

    Tighten 

    Tighten the bearing plate bolts to 22 N.m (16 lb-ft).

    Fig 21: Installing The Bearing Plate Bolts
    G00785680Courtesy of SUZUKI OF AMERICA CORP.
  30. Install the speedometer-driven gear and the speedometer-housing retaining bolt into the transaxle housing.

    Tighten 

    Tighten the speedometer housing retaining bolt to 4 N.m (35 lb-in).

    Fig 22: Installing The Speedometer-Driven Gear
    G00785681Courtesy of SUZUKI OF AMERICA CORP.
  31. Bolt the gearshift lever cover to the fixture KM-552.
  32. Position the fixture into the base KM-113-2.
  33. Install the gearshift rod, the shift finger lever, and the gearshift lever pin.
    Fig 23: Installing The Gearshift Rod
    G00785682Courtesy of SUZUKI OF AMERICA CORP.
  34. Install the snap ring, the bushing, the spring, and the intermediate lever.
    Fig 24: Installing The Intermediate Lever
    G00785683Courtesy of SUZUKI OF AMERICA CORP.
  35. Remove the gearshift lever cover from the base KM-113-2 and the fixture KM-552.
  36. Shift the transaxle into NEUTRAL.
  37. Install the gearshift lever cover and the gearshift lever cover bolts.

    Tighten 

    Tighten the gearshift lever cover bolts to 22 N.m (16 lb-ft).

    Fig 25: Installing The Gearshift Lever Cover
    G00785684Courtesy of SUZUKI OF AMERICA CORP.
  38. Install the transaxle cover and the transaxle cover bolts.

    Tighten 

    Tighten the transaxle cover bolts to 18 N.m (13 lb-ft).

    Fig 26: Installing The Transaxle Cover
    G00785685Courtesy of SUZUKI OF AMERICA CORP.
  39. Install the transaxle into the vehicle. Refer to TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION .
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