Fifth Gear Disassembly and Reassembly: Reassembly

Install countershaft 5th gear (1) to countershaft facing machined boss "A" inward.

Fig 1: Identifying Countershaft 5th Gear
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Apply transaxle oil to needle bearing, and install it to input shaft.
Install input shaft 5th gear (1) to input shaft.
Install special tool in order to stop shaft rotation.
Special Tool

(A): 09927-76060
Tighten new countershaft nut (2) to specified torque, and caulk nut securely.
Tightening torque

Countershaft nut a: 100 N.m (10.0 kg-m, 75.0 lb-ft)

Fig 2: Identifying Countershaft Nut And Input Shaft 5th Gear
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Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and synchronizer ring (4) as follows.

Fig 3: Identifying 5th Speed Synchronizer Sleeve, Hub, 5th Speed Synchronizer Levers And Synchronizer Ring
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1. Install hub (1) to 5th speed synchronizer sleeve (2) in specified direction as shown in figure.
  
  Fig 4: Identifying Hub And 5th Speed Synchronizer Sleeve
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2. Fit 5th speed synchronizer levers (1) to hub (2) in specified position as shown in figure.
  NOTE: Align protrusion "A" of 5th speed synchronizer levers (1) with groove of hub (2).
  
  Fig 5: Identifying 5th Speed Synchronizer Levers And Hub
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3. Install synchronizer ring (1) to hub (2) in specified direction as shown in figure.
  
  Fig 6: Identifying Synchronizer Ring And Hub
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Fit 5th gear shift fork (1) to sleeve (3) and hub (2) assembly, and install them into input shaft and gear shift shaft, aligning punch mark (4) with matching mark (5) on input shaft.

Fig 7: Aligning Punch Mark With Matching Mark On Input Shaft
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Tighten shift fork shaft bolt (2) to which thread lock cement has been applied.
"A": Thread lock cement 99000-32110Thread Lock Cement Super 1322

Tightening torque

Shift fork shaft bolt a: 10 N.m (1.0 kg-m, 7.5 lb-ft)
Using snap ring pliers, install new circlip (1) to input shaft (3).

Fig 8: Identifying Circlip And Input Shaft
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Clean mating surface of both left case and side cover (1), apply sealant to side cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate it with left case, and then tighten side cover bolts with specified torque.
"B": Sealant 99000-31260SUZUKI Bond No.1217G

Tightening torque

Side cover bolt a: 10 N.m (1.0 kg-m, 7.5 lb-ft)

Fig 9: Applying Sealant To Side Cover
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