Manual Transaxle Assembly Disassembly and Reassembly: Assembly

WARNING: This page is about a different variant/trim than selected.

Install differential assembly into right case.
Join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft (3) assemblies all together, then install them into right case (1) so as not to damage oil seal by input shaft spline.
NOTE:
- Input shaft right bearing on shaft can be installed into right case by tapping shaft with plastic hammer.
- Make sure that countershaft is engaged with final gear while installing.
  
  Fig 1: Installing Differential Assembly Into Right Case
  Courtesy of SUZUKI OF AMERICA CORP.
Install 5th & reverse gear shift shaft (1) with 5th & reverse gear shift guide shaft (2) into right case (5). Reverse gear shift arm (4) has to be joined with reverse gear shift lever (3) at the same time.

Fig 2: Installing 5th & Reverse Gear Shift Shaft With 5th & Reverse Gear Shift Guide Shaft Into Right Case
Courtesy of SUZUKI OF AMERICA CORP.
Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) into case (4) through idler gear and then align "A" in shaft with "B" in case.
NOTE:
- Make sure that washer (5) has been installed in shaft at above the gear.
- Confirm that reverse gear shift lever end has clearance 0.5 - 1 mm (0.02 - 0.04 in.) to idler gear groove.
  
  Fig 3: Inserting Reverse Gear Shaft Into Case
  Courtesy of SUZUKI OF AMERICA CORP.
Tighten reverse gear shift lever, bolts after applying thread lock cement.
: Thread lock cement 99000-32110

Tightening torque

Reverse gear shift lever bolt: 23 N.m (2.3 kg-m, 17.0 lb-ft)
Clean mating surfaces of both right and left cases, and apply sealant to right case (2) as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter then mate it with left case (1).
"B": Sealant 99000-31260
Tighten case bolts (3) from outside to specified torque.
Tightening torque

Transaxle case bolt b: 23 N.m (2.3 kg-m, 17.0 lb-ft)
Install reverse shaft bolt (4), to which thread lock cement has been applied, with aluminum washer and tighten it.
"A": Thread lock cement 99000-32110

Tightening torque

Reverse shaft bolt c: 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 4: Installing Reverse Shaft Bolt To Thread Lock
Courtesy of SUZUKI OF AMERICA CORP.
Install another case bolts from clutch housing side and tighten them to specification.
Tightening torque

Transaxle case bolt: 23 N.m (2.3 kg-m, 17.0 lb-ft)
Install differential side bearing outer race to left case, and tap and accustom outer race using special tool and plastic hammer.
CAUTION: Do not drive in a race with hammer. Driving it that way cause damage to bearing.

Special Tool
1. 09926-27610
  
  Fig 5: Installing Differential Side Bearing Outer Race
  Courtesy of SUZUKI OF AMERICA CORP.

Select a shim of differential side bearing as follows.

Measure depth "a" from left case end face (1) to side bearing outer race (2) using depth gauge.

Fig 6: Measuring Depth "A" From Left Case End Face To Side Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.
Measure height "b" of side bearing retainer with depth gauge.

Fig 7: Measuring Height "B" Of Side Bearing Retainer With Depth Gauge
Courtesy of SUZUKI OF AMERICA CORP.

Calculate clearance "a"-"b", and select a shim according to the following table.

Bearing shim

BEARING SHIM SPECIFICATIONS

Clearance "a"-"b"	Thickness of bearing shim to be installed
0.636 - 0.665 mm (0.0250 - 0.0261 in.)	0.75 mm (0.030 in.)
0.666 - 0.695 mm (0.0262 - 0.0273 in.)	0.78 mm (0.031 in.)
0.696 - 0.725 mm (0.0274 - 0.0285 in.)	0.81 mm (0.032 in.)
0.726 - 0.755 mm (0.0286 - 0.0297 in.)	0.84 mm (0.033 in.)
0.756 - 0.785 mm (0.0298 - 0.0309 in.)	0.87 mm (0.034 in.)
0.786 - 0.815 mm (0.0310 - 0.0320 in.)	0.90 mm (0.035 in.)
0.816 - 0.845 mm (0.0321 - 0.0332 in.)	0.93 mm (0.037 in.)
0.846 - 0.875 mm (0.0333 - 0.0344 in.)	0.96 mm (0.038 in.)
0.876 - 0.905 mm (0.0345 - 0.0356 in.)	0.99 mm (0.039 in.)
0.906 - 0.935 mm (0.0357 - 0.0368 in.)	1.02 mm (0.040 in.)
0.936 - 0.965 mm (0.0369 - 0.0379 in.)	1.05 mm (0.041 in.)
0.966 - 0.995 mm (0.0380 - 0.0391 in.)	1.08 mm (0.043 in.)
0.996 - 1.025 mm (0.0392 - 0.0403 in.)	1.11 mm (0.044 in.)
1.026 - 1.055 mm (0.0404 - 0.0415 in.)	1.14 mm (0.045 in.)
1.056 - 1.085 mm (0.0416 - 0.0427 in.)	1.17 mm (0.046 in.)
1.086 - 1.115 mm (0.0428 - 0.0438 in.)	1.20 mm (0.047 in.)
1.116 - 1.145 mm (0.0439 - 0.0450 in.)	1.23 mm (0.048 in.)
1.146 - 1.175 mm (0.0451 - 0.0462 in.)	1.26 mm (0.050 in.)
1.176 - 1.205 mm (0.0463 - 0.0474 in.)	1.29 mm (0.051 in.)
1.206 - 1.235 mm (0.0475 - 0.0486 in.)	1.32 mm (0.052 in.)
1.236 - 1.265 mm (0.0487 - 0.0498 in.)	1.35 mm (0.053 in.)
1.266 - 1.295 mm (0.0499 - 0.0509 in.)	1.38 mm (0.054 in.)
1.296 - 1.325 mm (0.0510 - 0.0521 in.)	1.41 mm (0.056 in.)

Install differential side bearing shim to left case (3).
Apply oil to new O-ring of side bearing retainer (2), and then install side bearing retainer with O-ring to left case (3).
Tighten side bearing retainer bolts (1) to specified torque.
NOTE:
- Install side bearing retainer with its punch mark (4) facing upward
Tightening torque

Side bearing retainer bolt a: 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 8: Tightening Side Bearing Retainer Bolts
Courtesy of SUZUKI OF AMERICA CORP.

Check locating springs for deterioration and replace with new ones as necessary.

Locating spring

LOCATING SPRING SPECIFICATIONS

Locating spring free length	Standard	Service limit
Low speed (2)	53.1 mm (2.091 in.)	50.5 mm (1.988 in.)
High speed (4)	45.9 mm (1.807 in.)	44.0 mm (1.732 in.)
5th & reverse (5)	29.9 mm (1.777 in.)	28.5 mm (1.122 in.)

Install steel ball (3) and locating spring for respective gear shift shaft and tighten with bolt (1) to which sealant has been applied.
"A": Sealant 99000-31260

Tightening torque

Gear shift locating bolt a: 13 N.m (1.3 kg-m, 9.5 lb-ft)

Fig 9: Installing Steel Ball And Locating Spring For Respective Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install back up lamp switch referring to BACK UP LAMP SWITCH REMOVAL AND INSTALLATION
To seat countershaft left bearing outer race (2) to bearing cone, tap cup by using special tool and plastic hammer.
Special Tool
1. 09913-70123
  
  Fig 10: Installing Back Up Lamp Switch
  Courtesy of SUZUKI OF AMERICA CORP.
Put a shim (3) on bearing outer race (4) provisionally, place straight edge (1) over it and compress it by hand through straight edge, and then measure "a" (Clearance between case surface (5) and straight edge) by using feeler gauge (6).
Clearance between case surface and straight edge

"a": 0.08 - 0.12 mm (0.0032 - 0.0047 in.)

By repeating step 19), select a suitable shim which adjusts clearance "a" to specification and put it on bearing outer race.

NOTE: Insert 0.1 mm (0.004 in.) feeler to know whether or not a shim fulfills specification quickly.

Available countershaft 5th gear shim thickness

COUNTERSHAFT 5TH GEAR SHIM THICKNESS SPECIFICATIONS

0.55 mm (0.021 in.)	0.7 mm (0.027 in.)	0.85 mm (0.033 in.)	1.0 mm (0.039 in.)
0.6 mm (0.023 in.)	0.75 mm (0.029 in.)	0.9 mm (0.035 in.)	1.05 mm (0.041 in.)
0.65 mm (0.025 in.)	0.8 mm (0.031 in.)	0.95 mm (0.037 in.)	1.1 mm (0.043 in.)

Fig 11: Measuring Clearance Between Case Surface And Straight Edge

Courtesy of SUZUKI OF AMERICA CORP.

Place left case plate (2) inserting its end in groove of shift guide shaft (4) and then tighten bolts (1) to which thread lock cement has been applied.
NOTE: After tightening bolts, make sure that countershaft can be rotated by hand feeling certain load.

"A": Thread lock cement 99000-32110

Tightening torque

Left case plate bolt a: 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 12: Placing Left Case Plate In Groove Of Shift Guide Shaft
Courtesy of SUZUKI OF AMERICA CORP.