Manual Transmission Unit Assembly

WARNING: This page is about a different variant/trim than selected.

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. Don't 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: Taping Rear Face Of Intermediate Case With Plastic Hammer
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Fix bearing with new C-ring (1) using special tool.
Special tool

(A): 09900-06107

Fig 4: Fixing Bearing With C-Ring Using Special Tool
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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 And Protrusion Of 4th Gear Synchronizer Ring
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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 And Rear Bearing To Intermediate Case
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Install reverse idle gear (1) and shaft (2).

Fig 7: Installing Reverse Idle Gear And Shaft
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Install main shaft and countershaft bearing plate (1) to intermediate case.
Tightening torque

Main and countershaft bearing plate bolt (a): 18 N.m (1.8 kg-m, 13.0 lb-ft)

Fig 8: Installing Main Shaft And Countershaft Bearing Plate To Intermediate Case
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Set pin (1) and thrust washer (2) to countershaft.

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

Fig 10: Installing Countershaft 5th Gear, Plate Spring, Circlip, 5th & Reverse Synchronizer Sleeve
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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
  
  (A): 09900-06107
  
  Fig 11: Installing Plate Spring To Countershaft 5th Gear And Fix Plate Spring With Circlip Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
2. Install 5th & 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
  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
  Courtesy of SUZUKI OF AMERICA CORP.
4. Install synchronizer key spring (1).
  
  Fig 14: Installing Synchronizer Key Spring
  Courtesy of SUZUKI OF AMERICA CORP.
5. Slide 5th & reverse synchronizer sleeve (1) until sliding surface of balk lever is locked into key location teeth of 5th & reverse synchronizer sleeve (1) with balk lever and synchronizer key spring pushed.
  
  Fig 15: Sliding 5th & Reverse Synchronizer Sleeve
  Courtesy of SUZUKI OF AMERICA CORP.
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
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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 Needle Bearing Into Countershaft 5th Gear Assembly
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Press-fit 5th speed synchronizer dog (1) to countershaft with hydraulic press (2) and special tool.
Special tool

(B): 09913-84510

Fig 18: Pressing-Fit 5th Speed Synchronizer Dog To Countershaft With Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.

Select circlip (1) that will make clearance in circlip groove 0.1 mm (0.0039 in.) or less.

CIRCLIP THICKNESS SPECIFICATIONS

ID mark	Circlip thickness	ID mark	Circlip thickness
A	2.80 - 2.85 mm (0.1102 - 0.1122 in.)	E	3.00 - 3.05 mm (0.1181-0.1201 in.)
B	2.85 - 2.90 mm (0.1122 - 0.1142 in.)	F	3.05 - 3.10 mm (0.1201 - 0.1220 in.)
C	2.90 - 2.95 mm (0.1142 - 0.1161 in.)	G	3.10 - 3.15 mm (0.1220 - 0.1240 in.)
D	2.95 - 3.00 mm (0.1162 - 0.1181 in.)

Fig 19: Determining Circlip Size

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Fix with circlip (1) as shown in the figure and check that countershaft 5th gear (2) turns lightly.

Fig 20: Checking Countershaft 5th Gear
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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).
Countershaft 5th gear thrust clearance

0.10 - 0.35 mm (0.0039 - 0.0138 in.)

Fig 21: Checking Countershaft 5th Gear Thrust Clearance Using Thickness Gauge
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Install reverse gear shift arm bracket (1) to intermediate case (2).
Tightening torque

Reverse gear shift arm bracket bolt (a): 18 N.m (1.8 kg-m, 13.0 lb-ft)

Fig 22: Installing Reverse Gear Shift Arm Bracket To Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse gear shift arm (1) to reverse gear shift fork (2) fixing it with new circlip (3), if necessary.

Fig 23: Installing Reverse Gear Shift Arm To Reverse Gear
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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 24: Inserting Spring And Ball To Reverse Gear Shift Fork
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Insert 5th & 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 & reverse guide shaft as specified direction. If failure to follow above-mentioned procedure, 5th & reverse guide shaft could result in wrong assembly which ball (5) installed to (6) hole for interlock pin.

Fig 25: Inserting 5th & Reverse Guide Shaft To Reverse Gear Shift Fork And Intermediate Case From Front Side Pushing Ball
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Insert ball (1) to reverse gear shift fork (2) and interlock pin (3) to intermediate case (4) using magnet.

Fig 26: Inserting Ball To Reverse Gear Shift Fork And Interlock Pin To Intermediate Case Using Magnet
Courtesy of SUZUKI OF AMERICA CORP.
Install 5th gear shaft (2) after fitting 5th gear shift fork (1) to 5th & reverse synchronizer sleeve (3).

Fig 27: Installing 5th Gear Shaft After Fitting 5th Gear Shift Fork To 5th & Reverse Synchronizer Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
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 28: Driving Spring Pin Into 5th Gear Shift Fork And Shaft Up To 5th Gear Shift Fork
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Install new circlips (1) to groove of 5th gear shift shaft (2) and 5th & reverse guide shaft (3) using lever (4) or the like and hammer.

Fig 29: Installing Circlips To Groove Of 5th Gear Shift Shaft And 5th & Reverse Guide Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Insert interlock pin (1) to intermediate case (2) using magnet (3).

Fig 30: Inserting Interlock Pin To Intermediate Case Using Magnet
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to straight pin (1) and install straight pin (1) to low speed gear shift shaft (2).
"A": Grease 99000-25010

Fig 31: 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 32: Installing Low Speed Gear Shift Fork And Low Speed Gear Shift Shaft
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Insert interlock pin (1) to intermediate case (2) using magnet (3).

Fig 33: Inserting Interlock Pin To Intermediate Case Using Magnet
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Install high speed gear shift fork (1) and high speed gear shift shaft (2).

Fig 34: Installing High Speed Gear Shift Fork And High Speed Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
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 35: Installing Circlips To High Speed Gear Shift Shaft And Low Speed Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
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

Low and high speed gear shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)

Fig 36: Installing Low Speed Gear Shift Fork Bolt And High Speed Gear Shift Fork Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Install locating balls (1), locating springs (2) and new locating screws (3).
Tightening torque

Locating screw (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 37: Installing Locating Balls, Locating Springs And Locating Screws
Courtesy of SUZUKI OF AMERICA CORP.
Place intermediate case assembly (1) upright as shown in the figure using workbench (2) or the like.

Fig 38: 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.
"A": Sealant 99000-31110

Fig 39: Applying Sealant Evenly To Front Case Side Of Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of front case (1) and install it to intermediate case.

Fig 40: Installing Front Case To Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Fix new C-rings (1, 2) to bearings as shown in the figure.
Special tool

(A): 09900-06107

Fig 41: Fixing C-Rings To Bearings
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of input shaft bearing retainer (1) and apply sealant evenly to input shaft bearing retainer (1).
"B": Sealant 99000-31110

Fig 42: Applying Sealant Evenly 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

Input shaft bearing retainer bolt (a): 17 N.m (1.7 kg-m, 12.5 lb-ft)

Fig 43: 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

(A): 09922-85811

Fig 44: Inserting Gear Shift Inner Shaft And Gear Shift Inner Lever To Rear Case
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).
"A": Sealant 99000-31110

Fig 45: Applying Sealant Evenly To Rear Case Side Of Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
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

Rear case to intermediate case bolt (a): 37 N.m (3.7 kg-m, 27.0 lb-ft)

Fig 46: Installing Rear Case To Intermediate Case With Tip End Of Gear Shift Shaft Inner Lever
Courtesy of SUZUKI OF AMERICA CORP.
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

Return spring reverse bolt (black color) (a): 37 N.m (3.7 kg-m, 27.0 lb-ft)

Return spring low bolt (b): 37 N.m (3.7 kg-m, 27.0 lb-ft)

Fig 47: Tightening Return Spring Low Bolt And Return Spring Reverse Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Install back-up light switch with new gasket.
Tightening torque Back-up light switch (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)

Fig 48: Installing Back-Up Light Switch With Gasket
Courtesy of SUZUKI OF AMERICA CORP.
Install clutch housing (3) and torque its bolts to specification.
NOTE: Use new two mounting bolts (1) as shown in the figure.

Tightening torque

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 49: Installing Clutch Release Fork And Release Bearing
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