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Home >> Suzuki >> 2006 >> Swift + >> Repair and Diagnosis >> Transmission >> Manual Transaxle - D16 >> Repair Instructions >> Transmission Assemble >> Assembly Procedure
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Assembly Procedure

    Fig 1: Input Drive 5th Gear Snap Ring
    GM1251668Courtesy of GENERAL MOTORS CORP.
  1. Join the mainshaft and the input shaft.
  2. Compress the snap ring at the base of the mainshaft and hold with the J 36633  (1). See Special Tools .
  3. Hold the snap ring at the base of the input drive shaft 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.
    6. Fig 2: 5th Gearshift Lever & Bearing Plate
    GM1251685Courtesy of GENERAL MOTORS CORP.
  6. Position the 1st-2nd gearshift fork.
  7. Install the 5th gearshift lever into the bearing plate.
    8. Fig 3: 3rd-4th Gearshift Fork, Rod & Holding Pin
    GM1251684Courtesy of GENERAL MOTORS CORP.
  8. Install the 3rd-4th gearshift rod/fork holding pin.
    9. Fig 4: Support Bracket & Bearing Plate
    GM1251683Courtesy of GENERAL MOTORS CORP.
  9. Install the support bracket onto the bearing plate.
    10. Fig 5: 1st-2nd Gearshift Rod/Fork & Bearing Plate
    GM1251777Courtesy of GENERAL MOTORS CORP.
  10. Install the 1st-2nd gearshift rod/fork onto the bearing plate.
    11. Fig 6: 1st-2nd Gearshift Fork & Holding Pin
    GM1251681Courtesy of GENERAL MOTORS CORP.
  11. Install the 1st-2nd gearshift fork holding pin.
    12. Fig 7: Support Bracket & Bolts
    GM1251678Courtesy of GENERAL MOTORS CORP.
  12. Install the support bracket bolts.

    Tighten:  Tighten the support bracket bolts to 7 N.m (62 lb in).

    13. Fig 8: Reverse Gearshift Rod/Fork Assembly & Bearing Plate
    GM1251675Courtesy of GENERAL MOTORS CORP.
  13. Install the reverse gearshift rod/fork on the bearing plate.
    14. Fig 9: Pin & Gearshift Rod/Fork Assembly
    GM1251674Courtesy of GENERAL MOTORS CORP.
  14. Install the reverse gearshift rod/fork holding pin.
    15. Fig 10: Spring & Rod Lock Pin
    GM1251672Courtesy of GENERAL MOTORS CORP.
  15. Install the rod lock pin and spring into the small plug hole.
    16. Fig 11: 4th Gearshift Rod Plugs
    GM1251778Courtesy of GENERAL MOTORS CORP.
  16. Install the 4th gearshift rod plugs.
    17. Fig 12: 5th Gearshift Connector & Bolts
    GM1251670Courtesy of GENERAL MOTORS 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).

    18. Fig 13: Input Drive 5th Gear & KM-554
    GM1251780Courtesy of GENERAL MOTORS CORP.
  18. Install the input drive 5th gear using the KM-554  (2) and the KM-334  (1). See Special Tools .
    19. Fig 14: Input Drive 5th Gear Snap Ring
    GM1251668Courtesy of GENERAL MOTORS CORP.
  19. Install the snap rings securing the 5th drive gear.
    20. Fig 15: Needle Bearing, Retaining Ring & Thrust Washers
    GM1251666Courtesy of GENERAL MOTORS CORP.
  20. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven 5th gear assembly.
    21. Fig 16: Brass Synchronizer Ring
    GM1251665Courtesy of GENERAL MOTORS CORP.
  21. Install the brass synchronizer ring onto the mainshaft-driven 5th gear assembly.
    22. Fig 17: 5th Drive Gear Synchronizer Gear & KM-554
    GM1251782Courtesy of GENERAL MOTORS CORP.
  22. Install the mainshaft-driven 5th gear assembly.
  23. Install the 5th drive gear synchronizer gear and the synchronizer sleeve using KM-554  (1). See Special Tools .
    24. Fig 18: Mainshaft-Driven 5th Speed Assembly Snap Ring
    GM1248226Courtesy of GENERAL MOTORS CORP.
  24. Install the snap ring holding the 5th speed-driven assembly.
    25. Fig 19: 5th Gear Fork & Bearing Plate
    GM1248225Courtesy of GENERAL MOTORS 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).

    26. Fig 20: View Of Transmission
    GM1248221Courtesy of GENERAL MOTORS CORP.
  26. Remove the bearing plate from the fixture.
  27. Shift the transaxle into the 2nd gear.
  28. Install the bearing plate, with the shafts attached, into the case.
    29. Fig 21: Bearing Plate Bolts
    GM1248220Courtesy of GENERAL MOTORS CORP.
  29. Install the bearing plate bolts.

    Tighten:  Tighten the bearing plate bolts to 22 N.m (16 lb ft).

    30. Fig 22: Locating Speedometer-Driven Gear
    GM1248215Courtesy of GENERAL MOTORS 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).

    31. Fig 23: Gearshift Rod & Shift Finger Lever
    GM1248213Courtesy of GENERAL MOTORS CORP.
  31. Bolt the gearshift lever cover to the KM-552  (2). See Special Tools .
  32. Position the fixture into the base J 3289-20  (3). See Special Tools .
  33. Install the gearshift rod (1), the shift finger lever, and the gearshift lever pin.
    34. Fig 24: Snap Ring, Bushing, Spring & Intermediate Lever
    GM1248211Courtesy of GENERAL MOTORS CORP.
  34. Install the snap ring, the bushing, the spring, and the intermediate lever.
  35. Remove the gearshift lever cover from the base and the fixture.
  36. Shift the transaxle into NEUTRAL.
    37. Fig 25: Locating Gearshift Lever Cover
    GM1248207Courtesy of GENERAL MOTORS 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).

    38. Fig 26: Transaxle Cover Bolts
    GM1248217Courtesy of GENERAL MOTORS 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 Transmission Replacement .
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