Countershaft Disassembly and Assembly: Assembly

Reference: COUNTERSHAFT AND REVERSE IDLER GEAR INSPECTION 

1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.
   Fig 1: Checking Oil Holes

   Courtesy of SUZUKI OF AMERICA CORP.
3. Drive in countershaft rear bearing (1) using special tool and hydraulic press.

   Special Tool 

   (A): 09913-84510 

   Fig 2: Installing Countershaft Rear Bearing

   Courtesy of SUZUKI OF AMERICA CORP.
4. Apply oil to countershaft gear needle bearing (6), and then install needle bearing, 2nd gear (5) and low speed synchronizer ring (7).
5. Assemble synchronizer sleeve (4) and hub (3) as follows.
   1. Fit low speed synchronizer sleeve to hub in specified direction as shown in figure.
   2. Insert 3 keys (2) to hub.
   3. Set springs (1) at specified position as shown in figure.

      Synchronizer key installation position 

      : A = B 

      Fig 3: Identifying Synchronizer Key Installation Position

      Courtesy of SUZUKI OF AMERICA CORP.
6. Drive in low speed synchronizer assembly (1) using special tool and hydraulic press.
   NOTE:

   • While press-fitting sleeve & hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly.
   • Check free rotation of 2nd gear after press-fitting sleeve & hub assembly.

   Special Tool 

   (A): 09913-84510 

   Fig 4: Installing Low Speed Synchronizer Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
7. Check 2nd gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

   2nd gear thrust clearance 

   "a": 0.10 - 0.30 mm (0.004 - 0.012 in.) 

   Fig 5: Identifying 2nd Gear Thrust Clearance

   Courtesy of SUZUKI OF AMERICA CORP.
8. Apply oil to countershaft gear needle bearing, and then countershaft low needle bush, needle bearing and 1st gear (1) to countershaft.
9. Press-fit countershaft reverse gear (2) using special tool and hydraulic press.

   Special Tool 

   (A): 09913-80113 

   Fig 6: Installing Countershaft Reverse Gear

   Courtesy of SUZUKI OF AMERICA CORP.
10. Press-fit countershaft front bearing (1) using special tool and hydraulic press.

    Special Tool 

    (A): 09913-84510 

    Fig 7: Installing Countershaft Front Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
11. Check low gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

    Low gear thrust clearance 

    "a": 0.10 - 0.30 mm (0.004 - 0.012 in.) 

    Fig 8: Identifying Low Gear Thrust Clearance

    Courtesy of SUZUKI OF AMERICA CORP.
12. Tighten countershaft front bearing nut to specified torque while locking countershaft in the same manner as Step  2) of "Disassembly" under Countershaft Disassembly and Assembly.
    CAUTION: Do not hold spline, gear teeth or abrasived surface of shaft with vise through "V" blocks or the like, otherwise shaft may be damaged.

    Tightening torque 

    Countershaft front bearing nut: 210 N.m (21.0 kg-m, 152.0 lbf-ft) 

13. Caulk countershaft front bearing nut using caulking tool and hammer.