Major Component Assy Assembly: Assembly

Join the mainshaft and the input shaft.
Compress the snap ring at the base of the mainshaft and hold with the snap ring retainer J-36633.
Hold the snap ring at the base of the input driveshaft with the snap ring pliers.
Install the mainshaft/input shaft assembly onto the bearing plate.
Release the mainshaft snap ring and the input shaft snap ring.

Fig 1: Identifying Snap Ring Retainer J-36633
Courtesy of SUZUKI OF AMERICA CORP.
Position the 1st - 2nd gearshift fork.
Install the 5th gearshift lever into the bearing plate.

Fig 2: Holding 5th Gearshift Lever
Courtesy of SUZUKI OF AMERICA CORP.
Install the 3rd - 4th gearshift rod/fork holding pin.

Fig 3: Identifying 3rd - 4th Gearshift Rod/Fork Holding Pin
Courtesy of SUZUKI OF AMERICA CORP.
Install the support bracket onto the bearing plate.

Fig 4: Locating Support Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Install the 1st - 2nd gearshift rod/fork onto the bearing plate.

Fig 5: Identifying 1st - 2nd Gearshift Rod/Fork
Courtesy of SUZUKI OF AMERICA CORP.
Install the 1st - 2nd gearshift fork holding pin.

Fig 6: Locating 1st - 2nd Gearshift Fork Holding Pin
Courtesy of SUZUKI OF AMERICA CORP.
Install the support bracket bolts.
Tighten:

Tighten the support bracket bolts to 7 N.m (62 lb-in).

Fig 7: Locating Support Bracket Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the reverse gearshift rod/fork onto the bearing plate.

Fig 8: Identifying Reverse Gearshift Rod/Fork
Courtesy of SUZUKI OF AMERICA CORP.
Install the reverse gearshift rod/fork holding pin.

Fig 9: Locating Reverse Gearshift Rod/Fork Holding Pin
Courtesy of SUZUKI OF AMERICA CORP.
Install the rod lock pin and spring into the small plug hole.

Fig 10: Identifying Rod Lock Pin And Spring
Courtesy of SUZUKI OF AMERICA CORP.
Install the 4th-gearshift rod plugs.

Fig 11: Identifying 4th-Gearshift Rod Plugs
Courtesy of SUZUKI OF AMERICA CORP.
Install the bolts and the 5th-gearshift connector onto the bearing plate, using the pawl.
Tighten:

Tighten the 5th-gearshift connector bolts to 7 N.m (62 lb-in).

Fig 12: Identifying 5th-Gearshift Connector Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the input drive 5th gear using the installer KM-554 and the installer sleeve KM-334.

Fig 13: Identifying Installer KM-554 And Installer Sleeve KM-334
Courtesy of SUZUKI OF AMERICA CORP.
Install the snap rings securing the 5th-drive gear.

Fig 14: Identifying Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven 5th-gear assembly.

Fig 15: Identifying Thrust Washers, Retaining Ring And Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install the brass synchronizer ring onto the mainshaft-driven 5th-gear assembly.

Fig 16: Identifying Brass Synchronizer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install the mainshaft-driven 5th-gear assembly.
Install the 5th-drive gear synchronizer gear and the synchronizer sleeve using installer KM-554.

Fig 17: Identifying Installer KM-554
Courtesy of SUZUKI OF AMERICA CORP.
Install the snap ring holding the 5th speed-driven assembly.

Fig 18: Identifying Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install the bolts and the 5th-gear fork onto the bearing plate.
Tighten:

Tighten the 5th-gear fork bolts to 22 N.m (16 lb-ft).

Fig 19: Identifying 5th-Gear Fork Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bearing plate from the fixture KM-552.
Shift the transaxle into 2nd gear.
Install the bearing plate, with the shafts attached, into the case.

Fig 20: Identifying Bearing Plate With Shafts Attached
Courtesy of SUZUKI OF AMERICA CORP.
Install the bearing plate bolts.
Tighten:

Tighten the bearing plate bolts to 22 N.m (16 lb-ft).

Fig 21: Identifying Bearing Plate Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the speedometer-driven gear and the speedometer-housing retaining bolt into the transaxle housing.
Tighten:

Tighten the speedometer housing retaining bolt to 4 N.m (35 lb-in).

Fig 22: Identifying Speedometer-Driven Gear And Speedometer-Housing Retaining Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Bolt the gearshift lever cover to the fixture KM-552.
Position the fixture into the base KM-113-2.
Install the gearshift rod, the shift finger lever, and the gearshift lever pin.

Fig 23: Identifying Fixture KM-552 And Base KM-113-2
Courtesy of SUZUKI OF AMERICA CORP.
Install the snap ring, the bushing, the spring, and the intermediate lever.
Remove the gearshift lever cover from the base KM-113-2 and the fixture KM-552.
Shift the transaxle into NEUTRAL.

Fig 24: Identifying Snap Ring, Bushing, Spring And Intermediate Lever
Courtesy of SUZUKI OF AMERICA CORP.
Install the reverse assist lever.
Install the reverse lever clip.

Fig 25: Identifying Reverse Assist Lever And Clip
Courtesy of SUZUKI OF AMERICA CORP.
Install the gearshift cover gasket.
Install the gearshift lever cover and the gearshift lever cover bolts.
Tighten:

Tighten the gearshift lever cover bolts to 22 N.m (16 lb-ft).

Fig 26: Identifying Gearshift Lever Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install the transaxle cover and the transaxle cover bolts.
Tighten:

Tighten the transaxle cover bolts to 18 N.m (13 lb-ft).
Install the transaxle into the vehicle. Refer to Transaxle Assembly Removal and Installation .

Fig 27: Identifying Transaxle Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.