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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
    G04717474Courtesy of SUZUKI OF AMERICA CORP.
  6. Position the 1st - 2nd gearshift fork.
  7. Install the 5th gearshift lever into the bearing plate.
    Fig 2: Installing 5th Gearshift Lever Into Bearing Plate
    G04717561Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the 3rd - 4th gearshift rod/fork holding pin.
    Fig 3: Identifying 3rd - 4th Gearshift Rod/Fork Holding Pin
    G04717470Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the support bracket onto the bearing plate.
    Fig 4: Locating Support Bracket Onto Bearing Plate
    G04717469Courtesy of SUZUKI OF AMERICA CORP.
  10. Install the 1st - 2nd gearshift rod/fork onto the bearing plate.
    Fig 5: Identifying First-Second Gearshift Rod/Fork
    G04717564Courtesy of SUZUKI OF AMERICA CORP.
  11. Install the 1st - 2nd gearshift fork holding pin.
    Fig 6: Locating First-Second Gearshift Fork Holding Pin
    G04717565Courtesy 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: Locating Support Bracket Bolts
    G04717466Courtesy of SUZUKI OF AMERICA CORP.
  13. Install the reverse gearshift rod/fork onto the bearing plate.
    Fig 8: Identifying Reverse Gearshift Rod/Fork At Bearing Plate
    G04717465Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the reverse gearshift rod/fork holding pin.
    Fig 9: Locating Reverse Gearshift Rod/Fork Holding Pin
    G04717568Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the rod lock pin and spring into the small plug hole.
    Fig 10: Identifying Rod Lock Pin And Spring Into Small Plug Hole
    G04717463Courtesy of SUZUKI OF AMERICA CORP.
  16. Install the 4th-gearshift rod plugs.
    Fig 11: Identifying Fourth-Gearshift Rod Plugs
    G04717570Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the bolts and the 5th-gearshift connector onto the bearing plate, using the pawl.

    Tighten: 

    Tighten the 5th-gearshift connector bolts to 7 N.m (62 lb-in).

    Fig 12: Identifying 5th-Gearshift Connector Bolts
    G04717461Courtesy of SUZUKI OF AMERICA CORP.
  18. Install the input drive 5th gear using the installer KM-554 and the installer sleeve KM-334.
    Fig 13: Installing Input Drive 5th Gear
    G04717572Courtesy of SUZUKI OF AMERICA CORP.
  19. Install the snap rings securing the 5th-drive gear.
    Fig 14: Identifying Snap Rings Securing Fifth-Drive Gear
    G04717459Courtesy of SUZUKI OF AMERICA CORP.
  20. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven 5th-gear assembly.
    Fig 15: Identifying Thrust Washers, Retaining Ring, And Needle Bearing
    G04717574Courtesy of SUZUKI OF AMERICA CORP.
  21. Install the brass synchronizer ring onto the mainshaft- driven 5th-gear assembly.
    Fig 16: Identifying Brass Synchronizer Ring
    G04717457Courtesy of SUZUKI OF AMERICA CORP.
  22. Install the mainshaft-driven 5th-gear assembly.
  23. Install the 5th-drive gear synchronizer gear and the synchronizer sleeve using installer KM-554.
    Fig 17: Installing 5th-Drive Gear Synchronizer Gear And Synchronizer Sleeve
    G04717576Courtesy of SUZUKI OF AMERICA CORP.
  24. Install the snap ring holding the 5th speed-driven assembly.
    Fig 18: Identifying Snap Ring Holding 5Th Speed-Driven Assembly
    G04717577Courtesy of SUZUKI OF AMERICA CORP.
  25. Install the bolts and the 5th-gear fork onto the bearing plate.

    Tighten: 

    Tighten the 5th-gear fork bolts to 22 N.m (16 lb-ft).

    Fig 19: Identifying 5th-Gear Fork Onto Bearing Plate
    G04717453Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove the bearing plate from the fixture KM-552.
  27. Shift the transaxle into 2nd gear.
  28. Install the bearing plate, with the shafts attached, into the case.
    Fig 20: Identifying Bearing Plate
    G04717451Courtesy 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: Identifying Bearing Plate Bolts
    G04717580Courtesy 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: Identifying Speedometer-Driven Gear Bolt
    G04717447Courtesy 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: Identifying Gearshift Rod, Shift Finger Lever, And Gearshift Lever Pin
    G04717582Courtesy 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: Identifying Snap Ring, Bushing, Spring, And Intermediate Lever
    G04717444Courtesy of SUZUKI OF AMERICA CORP.
  37. Install the reverse assist lever.
  38. Install the reverse lever clip.
    39. Fig 25: Installing Reverse Lever Clip And Assist Lever
    G00104938Courtesy of SUZUKI OF AMERICA CORP.
  39. Install the gearshift cover gasket.
  40. 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 26: Identifying Gearshift Lever Cover
    G04717442Courtesy of SUZUKI OF AMERICA CORP.
  41. Install the transaxle cover and the transaxle cover bolts.

    Tighten: 

    Tighten the transaxle cover bolts to 18 N.m (13 lb-ft).

  42. Install the transaxle into the vehicle. Refer to Transaxle Assembly Removal and Installation .
    Fig 27: Identifying Transaxle Cover Bolts
    G04717585Courtesy of SUZUKI OF AMERICA CORP.
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