Manual Transaxle Assembly Disassembly and Reassembly: Reassembly

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 (1) by tapping shaft with plastic hammer.
- Make sure that countershaft is engaged with final gear while installing.
Fig 1: Installing Input Shaft Assembly
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: Identifying 5th & Reverse Gear Shift Shaft, Guide Shaft And Case
Courtesy of SUZUKI OF AMERICA CORP.
Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) and washer (6) into case (4) through idler gear and then align bolt hole "a" in shaft with notch "b" in case.
Fasten reverse gear shift lever bolts (5) after applying thread lock cement.
"A": Thread lock cement 99000-32110Thread Lock Cement Super 1322

Tightening torque

Reverse gear shift lever bolt a: 23 N.m (2.3 kg-m, 17.0 lb-ft)

NOTE: Check to confirm that reverse gear shift lever end has clearance "c" to idler gear groove.

Distance between lever end and idler gear shaft

"c": 0.5 - 1.0 mm (0.02 - 0.04 in.)

Fig 3: Identifying Distance Between Lever End And Idler Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surfaces of both right and left cases, apply sealant to left case (2) as shown in the figure by such amount that its section is 1.5 mm (0.059 in.) in diameter then mate it with right case (1).
"A": Sealant 99000-31260SUZUKI Bond No.1217G
Tighten case bolts (3) from outside and tighten another case bolts from clutch housing side to specified torque.
Tightening torque

Transaxle case bolt a: 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 to specified torque.
"B": Sealant 99000-31260SUZUKI Bond No.1217G

Tightening torque

Reverse shaft bolt b: 21 N.m (21 kg-m, 15.5 lb-ft)

Fig 4: Identifying Reverse Shaft Bolt And Transaxle Case Bolt
Courtesy of SUZUKI OF AMERICA CORP.

Check locating springs (2, 4 and 5) for deterioration and replace with new ones as necessary.

Locating spring

SPRING FREE LENGTH CHART

Locating spring free length	Standard	Service limit
Low speed (2)	53.1 mm (2.091 in.)	47.8 mm (1.881 in.)
High speed (4)	45.9 mm (1.807 in.)	41.4 mm (1.629 in.)
5th & reverse (5)	29.9 mm (1.777 in.)	27.0 mm (1.062 in.)

Install steel balls (3) and locating springs (2, 4 and 5) for respective gear shift shaft and tighten bolts (1) to which thread lock cement has been applied.
"A": Thread lock cement 99000-32110Thread Lock Cement Super 1322

Tightening torque

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

Fig 5: Identifying Steel Balls And Springs
Courtesy of SUZUKI OF AMERICA CORP.
Install new snap ring (1) using snap ring pliers (4).

Fig 6: Installing Snap Ring Using Snap Ring Pliers
Courtesy of SUZUKI OF AMERICA CORP.
To seat countershaft left bearing outer race (2) to bearing cone, tap cup by using special tool and plastic hammer.
Special Tool

(A): 09913-70123

Fig 7: Installing Countershaft Left Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.
Before selecting shim, keep pushing outer race with the power of 100 N (10.0 kgf) and turn countershaft (2) 10 time or more.
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 - 0.13 mm (0.0032 - 0.0050 in.)

By repeating step 14), 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 CHART

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 8: Checking 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 99000-32110Thread Lock Cement Super 1322

Tightening torque

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

Fig 9: Identifying Left Case Plate, Shift Guide Shaft And Bolts
Courtesy of SUZUKI OF AMERICA CORP.