Countershaft Disassembly And Assembly: Assembly

Reference: COUNTERSHAFT AND REVERSE IDLE GEAR INSPECTION 

1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.
   Fig 1: Cleaning Components

   Courtesy of SUZUKI OF AMERICA CORP.
3. Drive in countershaft rear bearing (1) using special tool and hammer.

   Special Tool 

   1. 09913-84510 
      Fig 2: Identifying Special Tool Into Countershaft Rear Bearing

      Courtesy of SUZUKI OF AMERICA CORP.
4. Apply oil to countershaft gear needle bearing (6), and then install needle bearing, 2nd gear (5) and low speed synchronizer ring (7).
5. Assemble synchronizer sleeve (4) and hub (3) as follows.
   1. Fit low speed synchronizer sleeve to hub in specified direction as shown in figure.
   2. Insert 3 keys (2) to hub.
   3. Set springs (1) at specified position as shown in figure.

   Synchronizer key installation position 

   : A = B 

   Fig 3: Identifying Synchronizer Key Installation Position

   Courtesy of SUZUKI OF AMERICA CORP.
6. Drive in low speed synchronizer assembly (1) using special tool and hammer.
   NOTE:

   • While press-fitting sleeve & hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly.
   • Check free rotation of 2nd gear after press-fitting sleeve & hub assembly.

   Special Tool 

   1. 09913-84510 
   Fig 4: Identifying Special Tool On Low Speed Synchronizer Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
7. Check 2nd gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

   2nd gear thrust clearance 

   "a": 0.10-0.30 mm (0.004-0.012 in.) 

   Fig 5: Identifying 2nd Gear Thrust Clearance Specification

   Courtesy of SUZUKI OF AMERICA CORP.
8. Apply oil to countershaft gear needle bearing, and then countershaft low needle bush, needle bearing and 1st gear (1) to countershaft.
9. Press-fit countershaft reverse gear (2) using special tool and hammer.

   Special Tool 

   1. 09913-80113 
   Fig 6: Identifying Special Tool On Countershaft Reverse Gear

   Courtesy of SUZUKI OF AMERICA CORP.
10. Press-fit countershaft front bearing (1) using special tool and hammer.

    Special Tool 

    1. 09913-84510 
       Fig 7: Identifying Special Tool On Countershaft Front Bearing

       Courtesy of SUZUKI OF AMERICA CORP.
11. Check low gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

    Low gear thrust clearance 

    "a": 0.10-0.30 mm (0.004-0.012 in.) 

    Fig 8: Identifying Low Gear Thrust Clearance Specifications

    Courtesy of SUZUKI OF AMERICA CORP.
12. Tighten countershaft front bearing nut to specified torque while locking counter shaft in the same manner as step  2 of "Disassembly" under Countershaft Disassembly and Assembly  .
    CAUTION: Do not hold spline, gear teeth or abrasive surface of shaft with vise through "V" blocks or the like, otherwise shaft may be damaged.

    Tightening torque 

    Countershaft front bearing nut: 210 N.m (21.0 kg-m, 152.0 lb-ft) 

13. Caulk countershaft front bearing nut using caulking tool and hammer.