Gear Shift Lever Case Disassembly and Assembly: Assembly

1. Wash and inspect each part and replace if necessary. Also check the following item and correct whatever necessary carefully by using reamer, oilstone and the like, wash it thoroughly and reassemble it. Item to be checked is;
   • Shift shaft should go into case smoothly.
2. Insert shift shaft (1) as shown in figure while making sure that inner parts are in proper direction.
   NOTE:

   • Cut off portion (3) in shift shaft (1) should face downward when shift shaft (1) is installed.
   • Shift lever (2) should be installed at the same time.
   Fig 1: Inserting Shift Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
3. Drive in spring pins (2) for gear shift lever (5) and shift arm (7).
   NOTE: When driving in spring pins, position their slits 180° +/- 30° apart.

   Special tool 

   (A): 09925-78210 

4. Apply sealant to new case plug (8) and drive it into lever case (1).

   "A": Sealant 99000-31110 

   Fig 2: Installing Spring Pins

   Courtesy of SUZUKI OF AMERICA CORP.
5. Clean mating surface of gear shift lever case (1) and case plate (2), and then apply sealant evenly to surface of gear shift lever case (1).

   "A": Sealant 99000-31110 

6. Tighten screws to specified torque.

   Tightening torque 

   Gear shift lever case plate screw (b): 6 N.m (0.6 kg-m, 4.5 lb-ft) 

   Fig 3: Cleaning Mating Surface Of Gear Shift Lever Case And Case Plate

   Courtesy of SUZUKI OF AMERICA CORP.
7. Install gear shift lever case (2) to transmission without using sealant for functional check.
8. Install shift control lever and check to make sure that it shifts smoothly according to shift pattern as shown in the figure.

"C": Thread lock cement 99000-32020 

Tightening torque 

Transmission control lever locating bolt (a): 17 N.m (1.7 kg-m, 12.5 lb-ft) 

Fig 4: Installing Shift Control Lever

Courtesy of SUZUKI OF AMERICA CORP.