Manual Transmission Rear Case Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2006 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.

Check that interlock cam component (1) moves smoothly in both turning direction and sliding direction.

Fig 1: Identifying Interlock Cam Component Moves Smoothly
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Insert interlock cam component (1) to rear case (2).

Fig 2: Identifying Interlock Cam Component & Rear Case
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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: Identifying Interlock Cam Component, Drive Interlock Cam Pin & Special Tool
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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: Identifying Interlock Cam Plug
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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: Identifying Oil Seal Special Tool
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Install countershaft gutter (2) to transmission rear case (1).

Fig 6: Identifying Countershaft Gutter & Transmission Rear Case

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