Mainshaft Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2007 Suzuki Reno, 2007 Suzuki Forenza, 2006 Suzuki Reno, and 2006 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

Install the mainshaft bearing.

Fig 1: Installing Mainshaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install the ring, the thrust washer, and the 4th-gear needle bearing.

Fig 2: Installing Ring, Thrust Washer, And 4th-Gear Needle Bearing
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Attach the synchronizer blocking ring to the 4th gear.

Fig 3: Attaching Synchronizer Blocking Ring To Fourth Gear
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Install the 4th-gear assembly.

Fig 4: Identifying Fourth-Gear Assembly
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Install the 3rd - 4th gear synchronizer containing the synchronizer spring.

Fig 5: Identifying Third-Fourth Gear Synchronizer Containing Synchronizer Spring
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Install the snap ring and the washer around the mainshaft.

Fig 6: Installing Snap Ring And Washer Around Mainshaft
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Install the synchronizer sleeve containing the keys and the spring.

Fig 7: Identifying Synchronizer Sleeve Containing Keys And Spring
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Install the 3rd-gear needle bearing.

Fig 8: Identifying Third-Gear Needle Bearing
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Attach the synchronizer blocking ring to the 3rd gear.

Fig 9: Attaching Synchronizer Blocking Ring To Third Gear
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Install the 3rd-gear assembly.

Fig 10: Installing 3rd-Gear Assembly
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Install the thrust washer and the ring.

Fig 11: Installing Thrust Washer And Ring
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Install the 2nd-gear needle bearing.

Fig 12: Installing 2nd-Gear Needle Bearing
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Install the 2nd gear.

Fig 13: Installing Second Gear
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Install the 1st - 2nd gear blocking ring.

Fig 14: Identifying First-Second Gear Blocking Ring
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Install the 1st - 2nd synchronizer gear.

Fig 15: Installing First-Second Synchronizer Gear
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Install the washer and the snap ring.

Fig 16: Installing Washer And Snap Ring
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Install the 1st-gear needle bearing.

Fig 17: Installing 1st-Gear Needle Bearing
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Install the keys onto the 1st - 2nd synchronizer gear.

Fig 18: Identifying Keys Onto First-Second Synchronizer Gear
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Install the synchronizer hub sleeve containing the synchronizer spring.

Fig 19: Identifying Synchronizer Hub Sleeve Containing Synchronizer Spring
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Install the outer blocking ring.
Install the mainshaft wear plate, the flat-type 1st gear needle bearing, and the 1st gear.

Fig 20: Installing Outer Blocking Ring
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Install the snap ring.

Fig 21: Installing Snap Ring
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Press on the mainshaft bearing.

Fig 22: Pressing On Mainshaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.