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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: Installing Mainshaft/Input Shaft Assembly Onto Bearing Plate
    G04103839Courtesy of SUZUKI OF AMERICA CORP.
  6. Position the first-second gearshift fork.
  7. Install the fifth gearshift lever into the bearing plate.
    Fig 2: Positioning First-Second Gearshift Fork
    G04103840Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the third-fourth gearshift rod/fork holding pin.
    Fig 3: Installing Third-Fourth Gearshift Rod/Fork Holding Pin
    G04103841Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the support bracket onto the bearing plate.
    Fig 4: Installing Support Bracket Onto Bearing Plate
    G04103842Courtesy of SUZUKI OF AMERICA CORP.
  10. Install the first-second gearshift rod/fork onto the bearing plate.
    Fig 5: Installing First-Second Gearshift Rod/Fork Onto Bearing Plate
    G04103843Courtesy of SUZUKI OF AMERICA CORP.
  11. Install the first-second gearshift fork holding pin.
    Fig 6: Installing First-Second Gearshift Fork Holding Pin
    G04103844Courtesy 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 Support Bracket Bolts
    G04103845Courtesy of SUZUKI OF AMERICA CORP.
  13. Install the reverse gearshift rod/fork onto the bearing plate.
    Fig 8: Installing Reverse Gearshift Rod/Fork Onto Bearing Plate
    G04103846Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the reverse gearshift rod/fork holding pin.
    Fig 9: Installing Reverse Gearshift Rod/Fork Holding Pin
    G04103847Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the rod lock pin and spring into the small plug hole.
    Fig 10: Installing Rod Lock Pin And Spring Into Small Plug Hole
    G04103848Courtesy of SUZUKI OF AMERICA CORP.
  16. Install the fourth-gearshift rod plugs.
    Fig 11: Installing Fourth-Gearshift Rod Plugs
    G04103849Courtesy 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: Installing Bolts And Fifth-Gearshift Connector Onto Bearing Plate
    G04103850Courtesy 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 Input Drive Fifth Gear
    G04103851Courtesy of SUZUKI OF AMERICA CORP.
  19. Install the snap rings securing the fifth-drive gear.
    Fig 14: Installing Snap Rings Securing Fifth-Drive Gear
    G04103852Courtesy 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, Retaining Ring, And Needle Bearing Into Mainshaft-Driven Fifth-Gear Assembly
    G04103853Courtesy of SUZUKI OF AMERICA CORP.
  21. Install the brass synchronizer ring onto the mainshaft-driven fifth-gear assembly.
    Fig 16: Installing Brass Synchronizer Ring Onto Mainshaft-Driven Fifth-Gear Assembly
    G04103854Courtesy 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 Fifth-Drive Gear Synchronizer Gear And Synchronizer Sleeve
    G04103855Courtesy of SUZUKI OF AMERICA CORP.
  24. Install the snap ring holding the fifth speed-driven assembly.
    Fig 18: Installing Snap Ring
    G04103856Courtesy 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 Bolts And Fifth-Gear Fork Onto Bearing Plate
    G04103857Courtesy 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 Bearing Plate, With Shafts Attached, Into Case
    G04103858Courtesy 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 Bearing Plate Bolts
    G04103859Courtesy 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 Speedometer-Driven Gear
    G04103860Courtesy 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: Positioning Fixture Into Base KM-113-2
    G04103861Courtesy of SUZUKI OF AMERICA CORP.
  34. Install the snap ring, the bushing, the spring, and the intermediate lever.
  35. Remove the gearshift lever cover from the base KM-113-2 and the fixture KM-552.
  36. Shift the transaxle into NEUTRAL.
    Fig 24: Installing Snap Ring, Bushing, Spring, And Intermediate Lever
    G04103862Courtesy of SUZUKI OF AMERICA CORP.
  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 Gearshift Lever Cover And Gearshift Lever Cover Bolts
    G04103863Courtesy 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).

  39. Install the transaxle into the vehicle. Refer to "TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION :".
    Fig 26: Installing Transaxle Cover
    G04103864Courtesy of SUZUKI OF AMERICA CORP.
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