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Home >> Suzuki >> 2005 >> XL-7 EX, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Manual Transmission) >> H27 Engine Model >> Repair Instructions >> Manual Transmission Rear Case Disassembly and Assembly >> Assembly
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Manual Transmission Rear Case Disassembly and Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Check that interlock cam component (1) moves smoothly in both turning direction and sliding direction.
    Fig 1: Checking Interlock Cam Component
    G04100534Courtesy of SUZUKI OF AMERICA CORP.
  2. Insert interlock cam component (1) to rear case (2).
    Fig 2: Inserting Interlock Cam Component To Rear Case
    G04100535Courtesy of SUZUKI OF AMERICA CORP.
  3. Set interlock cam component (1) as shown in the figure and drive interlock cam pin (2) using special tool.

    Special tool 

    (A): 09922-85811 

    Fig 3: Setting Interlock Cam Component
    G04100536Courtesy of SUZUKI OF AMERICA CORP.
  4. Install new interlock cam plug (1) and tighten it to specification.

    Tightening torque 

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

    Fig 4: Installing Interlock Cam Plug
    G04100537Courtesy of SUZUKI OF AMERICA CORP.
  5. Install new 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
    G04100538Courtesy of SUZUKI OF AMERICA CORP.
  6. Install countershaft gutter (2) to transmission rear case (1).
Fig 6: Installing Countershaft Gutter To Transmission Rear Case
G04100539Courtesy of SUZUKI OF AMERICA CORP.