LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2004 >> Vitara 4WD, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission >> Repair Instructions >> Manual Transmission Rear Case Disassembly and Assembly >> Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

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 That Interlock Cam Component Movement
    G00798290Courtesy of SUZUKI OF AMERICA CORP.
  2. Insert interlock cam component (1) to rear case.
    Fig 2: Inserting Interlock Cam Component To Rear Case
    G00798291Courtesy of SUZUKI OF AMERICA CORP.
  3. Set interlock cam component (1) as shown in the figure and drive pin by using special tool (A).

    Special tool 

    (A): 09922-85811

    Fig 3: Setting Interlock Cam Component
    G00798292Courtesy of SUZUKI OF AMERICA CORP.
  4. Apply thread lock cement to thread of interlock cam plug (1) and tighten it to specification.

    "A": Thread lock cement 99000-32020 

    Tightening torque 

    Interlock cam plug (a): 19 N.m (1.9 kg-m, 14.0 lb-ft) 

    Fig 4: Tightening Interlock Cam Plug
    G00798293Courtesy of SUZUKI OF AMERICA CORP.
  5. Install 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 

    (B): 09913-75510

    Fig 5: Installing Oil Seal To Rear Case
    G00798294Courtesy of SUZUKI OF AMERICA CORP.
  6. Install counter shaft gutter (2) to transmission rear case (1).
    Fig 6: Installing Counter Shaft Gutter To Transmission Rear Case
    G00798295Courtesy of SUZUKI OF AMERICA CORP.