Manual Transmission Unit Reassembly

Reference: MANUAL TRANSMISSION ASSEMBLY COMPONENTS 

Reference: MANUAL TRANSMISSION UNIT DISASSEMBLY 

Reference: LOCATING SPRING INSPECTION 

1. Assemble input shaft assembly (1), countershaft assembly (2), high speed gear shift fork (3) and low speed gear shift fork (4), then install them all together into front case (5).
   CAUTION: Take care not to damage oil seal lip by input shaft, or oil leakage may take place.
   Fig 1: Identifying Input Shaft Assembly, Countershaft Assembly, High And Low Speed Gear Shift Fork

   Courtesy of SUZUKI OF AMERICA CORP.
2. Install new input shaft front bearing snap ring (1) using special tool.

   Special Tool 

   (A): 09900-06106 

   Fig 2: Installing Input Shaft Front Bearing Snap Ring

   Courtesy of SUZUKI OF AMERICA CORP.
3. Install low speed gear shift shaft (1) and low gear shift inverse lever (2) and tighten with new bolt (3).
   CAUTION: Be sure to use new bolts with pre-coated adhesive. Otherwise, bolts may loosen.

   Tightening torque 

   Low gear shift inverse lever bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

   Fig 3: Identifying Low Speed Gear Shift Shaft And Low Gear Shift Inverse Lever

   Courtesy of SUZUKI OF AMERICA CORP.
4. Fit 5th & reverse gear shift fork (1) to 5th speed synchronizer sleeve (2), and install them into input shaft and front case in specified direction as shown in figure.
   Fig 4: Identifying 5th & Reverse Gear Shift Fork Position

   Courtesy of SUZUKI OF AMERICA CORP.
5. Set reverse idler gear (1), reverse gear shift lever (2) and reverse gear shaft washer (4), insert reverse gear shaft (3) into case through idler gear and then align hole "B" in shaft with protrusion "A" in case.
   Fig 5: Identifying Reverse Idler Gear, Reverse Gear Shift Lever And Reverse Gear Shaft Washer

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install oil gutter.
7. Install 5th speed synchronizer levers and 5th speed synchronizer ring as follows.
   1. Fit 5th speed synchronizer levers (1) to hub (2) aligning protrusion "A" of 5th speed synchronizer levers with groove of hub.
      Fig 6: Identifying 5th Speed Synchronizer Levers And Hub

      Courtesy of SUZUKI OF AMERICA CORP.
   2. Install synchronizer ring (1) to hub (2) in specified direction as shown in figure.
      Fig 7: Identifying Synchronizer Ring And Hub

      Courtesy of SUZUKI OF AMERICA CORP.
8. Install input shaft needle bearing to end of input shaft.
9. Clean mating surfaces of both front and rear cases, and uniformly apply sealant to front case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, and then mate it with rear case.

   "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) 

   Fig 8: Applying Sealant To Front Case

   Courtesy of SUZUKI OF AMERICA CORP.
10. Install rear case to front case. Tighten case bolts (1) to specified torque.

    Tightening torque 

    Transmission case bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

11. Install new reverse shaft bolt (2) and new washer, and tighten it to specified torque.
    CAUTION: Be sure to use new bolts with pre-coated adhesive. Otherwise, bolts may loosen.

    Tightening torque 

    Reverse shaft bolt (b): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

12. Install back up light switch (3) referring to BACK UP LIGHT SWITCH REMOVAL AND INSTALLATION .
    Fig 9: Identifying Case Bolts, Back Up Light Switch And Reverse Shaft Bolt

    Courtesy of SUZUKI OF AMERICA CORP.
13. Apply grease to locating balls (1) and locating springs (2), then install them.

    Tighten new gear shift locating bolts (3) to specified torque.

    CAUTION: Be sure to use new bolts with pre-coated adhesive. Otherwise, bolts may loosen.

    "A": Grease 99000-25011 (SUZUKI Super Grease A) 

    Tightening torque 

    Gear shift locating bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

    Fig 10: Identifying Gear Shift Locating Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
14. Install output shaft assembly into rear case.
15. Select a countershaft shim and output shaft shim as follows.
    1. Measure depth "a" from mating surface of adapter case (1) to face processed for installation of countershaft rear bearing (2) and measure depth "c" from mating surface of adapter case to face processed for installation of output shaft rear bearing (5) using vernier caliper.
    2. Measure height "b" from mating surface of rear case (3) to countershaft rear bearing (4) and "d" from mating surface of rear case (3) to output shaft bearing (6) using vernier caliper.
    3. Calculate "a" - "b" and "c" - "d", and select a shim according to the following table.

       Countershaft shim selection table 

       COUNTERSHAFT SHIM SELECTION CHART
       
       

       Clearance "a" - "b"	Thickness of countershaft shim
       1.15 - 1.24 mm (0.046 - 0.048 in.)	0.90 mm (0.035 in.)
       1.25 - 1.34 mm (0.050 - 0.052 in.)	1.00 mm (0.039 in.)
       1.35 - 1.44 mm (0.054 - 0.056 in.)	1.10 mm (0.043 in.)
       1.45 - 1.54 mm (0.057 - 0.060 in.)	1.20 mm (0.047 in.)
       1.55 - 1.64 mm (0.061 - 0.064 in.)	1.30 mm (0.051 in.)
       1.65 - 1.74 mm (0.065 - 0.068 in.)	1.40 mm (0.055 in.)
       1.75 - 1.84 mm (0.069 - 0.072 in.)	1.50 mm (0.059 in.)
       1.85 - 1.94 mm (0.073 - 0.076 in.)	1.60 mm (0.063 in.)
       1.95 - 2.04 mm (0.077 - 0.080 in.)	1.70 mm (0.067 in.)
       2.05 - 2.14 mm (0.081 - 0.084 in.)	1.80 mm (0.071 in.)
       2.15 - 2.24 mm (0.085 - 0.088 in.)	1.90 (0.90 + 1.00) mm (0.075 (0.035 + 0.039) in.)

       Output shaft shim selection table 

       OUTPUT SHAFT SHIM SELECTION CHART
       
       

       Clearance "c" - "d"	Thickness of output shaft shim
       0.1 - 0.19 mm (0.004 - 0.007 in.)	-
       0.2 - 0.29 mm (0.008 - 0.011 in.)	0.1 mm (0.004 in.)
       0.3 - 0.39 mm (0.012 - 0.015 in.)	0.2 mm (0.008 in.)
       0.4 - 0.49 mm (0.016 - 0.019 in.)	0.3 mm (0.012 in.)
       0.5 - 0.59 mm (0.020 - 0.023 in.)	0.4 mm (0.016 in.)
       0.6 - 0.69 mm (0.024 - 0.027 in.)	0.5 mm (0.020 in.)
       0.7 - 0.79 mm (0.028 - 0.031 in.)	0.6 mm (0.024 in.)
       0.8 - 0.89 mm (0.032 - 0.035 in.)	0.7 mm (0.028 in.)
       0.9 - 0.99 mm (0.036 - 0.038 in.)	0.8 mm (0.031 in.)
       1.0 - 1.09 mm (0.040 - 0.042 in.)	0.9 mm (0.035 in.)
       1.1 - 1.19 mm (0.044 - 0.046 in.)	1.0 mm (0.039 in.)
       1.2 - 1.29 mm (0.048 - 0.050 in.)	1.1 mm (0.043 in.)
       1.3 - 1.39 mm (0.052 - 0.054 in.)	1.2 mm (0.047 in.)

       Fig 11: Measuring Height From Mating Surface Of Rear Case To Countershaft Rear Bearing

       Courtesy of SUZUKI OF AMERICA CORP.
16. Install selected countershaft shim and output shaft shim to adapter case.
17. Clean mating surface of both rear case (1) and adapter case, and uniformly apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, and then mate it with adapter case.

    "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) 

18. Install rear case to adapter case. Tighten case bolts (2) to specified torque.

    Tightening torque 

    Adapter case bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

    Fig 12: Identifying Adapter Case Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
19. Install transfer assembly or extension case assembly to transmission assembly. Tighten transfer or extension case fastening bolts to specified torque referring to TRANSFER ASSEMBLY COMPONENTS: MOTOR-SHIFT TYPE (TRANSFER WITH SHIFT ACTUATOR) or EXTENSION CASE ASSEMBLY COMPONENTS .
20. Install gear shift lever front case assembly referring to GEAR SHIFT LEVER FRONT CASE ASSEMBLY REMOVAL AND INSTALLATION .
21. Install clutch operating cylinder assembly to transmission front case referring to CLUTCH OPERATING CYLINDER ASSEMBLY REMOVAL AND INSTALLATION .