Manual Transaxle Assembly Disassembly and Reassembly: Reassembly

Reference: RIGHT CASE DISASSEMBLY AND REASSEMBLY 

Reference: LEFT CASE DISASSEMBLY AND REASSEMBLY 

Reference: INPUT SHAFT DISASSEMBLY AND REASSEMBLY 

Reference: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY 

Reference: DIFFERENTIAL DISASSEMBLY AND REASSEMBLY 

Reference: GEAR SHIFT SHAFT AND FORK INSPECTION 

1. Install differential assembly into right case.
2. Join input shaft assembly (5), countershaft assembly (4), low speed gear shift shaft (2), high speed gear shift shaft (3), 5th and 6th gear shift shaft (6), reverse gear shift shaft (7) and reverse gears (8) 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: Identifying Manual Transaxle Assembly Components

     Courtesy of SUZUKI OF AMERICA CORP.
3. Select input shaft shim and reverse gear washer as follows.
   1. Measure depth "a" of left case (1) and "b" of right case (2) and measure depth "e" of left case and "f" of right case.
   2. Measure distance "c" of input shaft assembly (3) and measure distance "g" of reverse gear assembly (4).
   3. Calculate the clearance of "d" and "h" by the following expressions.
      CLEARANCE REFERENCE CHART
      
      

      Clearance "d" = Depth "a" + Depth "b" - Distance "c"

      CLEARANCE REFERENCE CHART
      
      

      Clearance "h" = Depth "e" + Depth "f" - Distance "g"

      Fig 2: Input Shaft Shim And Reverse Gear Washer Specifications

      Courtesy of SUZUKI OF AMERICA CORP.
   4. Select shims closest to clearance "d" and select washer closest to clearance "h" from among the following available sizes.

      Available shim thickness 

      SHIM THICKNESS SPECIFICATIONS
      
      

      Clearance "d"	Select shim
      1.055 - 1.095 mm (0.0415 - 0.0431 in.)	1.04 mm (0.0409 in.)
      1.095 - 1.135 mm (0.0431 - 0.0447 in.)	1.08 mm (0.0425 in.)
      1.135 - 1.175 mm (0.0447 - 0.0463 in.)	1.12 mm (0.0441 in.)
      1.175 - 1.215 mm (0.0463 - 0.0478 in.)	1.16 mm (0.0457 in.)
      1.215 - 1.255 mm (0.0478 - 0.0494 in.)	1.20 mm (0.0472 in.)
      1.255 - 1.295 mm (0.0494 - 0.0510 in.)	1.24 mm (0.0488 in.)
      1.295 - 1.335 mm (0.0510 - 0.0526 in.)	1.28 mm (0.0504 in.)
      1.335 - 1.375 mm (0.0526 - 0.0541 in.)	1.32 mm (0.0520 in.)
      1.375 - 1.415 mm (0.0541 - 0.0557 in.)	1.36 mm (0.0535 in.)
      1.415 - 1.455 mm (0.0557 - 0.0573 in.)	1.40 mm (0.0551 in.)
      1.455 - 1.495 mm (0.0573 - 0.0589 in.)	1.44 mm (0.0567 in.)
      1.495 - 1.535 mm (0.0589 - 0.0604 in.)	1.48 mm (0.0583 in.)
      1.535 - 1.575 mm (0.0604 - 0.0620 in.)	1.52 mm (0.0598 in.)
      1.575 - 1.615 mm (0.0620 - 0.0636 in.)	1.56 mm (0.0614 in.)
      1.615 - 1.655 mm (0.0636 - 0.0651 in.)	1.60 mm (0.0630 in.)
      1.655 - 1.695 mm (0.0651 - 0.0667 in.)	1.64 mm (0.0646 in.)
      1.695 - 1.735 mm (0.0667 - 0.0683 in.)	1.68 mm (0.0661 in.)
      1.735 - 1.775 mm (0.0683 - 0.0698 in.)	1.72 mm (0.0677 in.)
      1.775 - 1.815 mm (0.0698 - 0.0714 in.)	1.76 mm (0.0693 in.)
      1.815 - 1.855 mm (0.0715 - 0.0730 in.)	1.80 mm (0.0709 in.)
      1.855 - 1.895 mm (0.0730 - 0.0746 in.)	1.84 mm (0.0724 in.)
      1.895 - 1.935 mm (0.0746 - 0.0761 in.)	1.88 mm (0.0740 in.)
      1.935 - 1.975 mm (0.0761 - 0.0777 in.)	1.92 mm (0.0756 in.)
      1.975 - 2.015 mm (0.0777 - 0.0793 in.)	1.96 mm (0.0772 in.)

      Available washer thickness 

      WASHER THICKNESS SPECIFICATIONS
      
      

      Clearance "h"	Select washer
      1.815 - 1.895 mm (0.0715 - 0.0746 in.)	1.76 mm (0.0694 in.)
      1.895 - 1.975 mm (0.0746 - 0.0778 in.)	1.84 mm (0.0724 in.)
      1.975 - 2.055 mm (0.0778 - 0.0809 in.)	1.92 mm (0.0760 in.)
      2.055 - 2.135 mm (0.0809 - 0.0841 in.)	2.00 mm (0.0787 in.)
      2.135 - 2.215 mm (0.0841 - 0.0872 in.)	2.08 mm (0.0819 in.)
      2.215 - 2.295 mm (0.0872 - 0.0904 in.)	2.16 mm (0.0850 in.)
      2.295 - 2.375 mm (0.0904 - 0.0935 in.)	2.24 mm (0.0882 in.)
      2.375 - 2.455 mm (0.0935 - 0.0967 in.)	2.32 mm (0.0913 in.)
      2.455 - 2.535 mm (0.0967 - 0.0998 in.)	2.40 mm (0.0945 in.)
      2.535 - 2.615 mm (0.0998 - 0.1030 in.)	2.48 mm (0.0976 in.)

4. Install reverse gear lever (1) and then tighten new reverse gear lever bolts (2) to specified torque.

   Tightening torque 

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

   Fig 3: Identifying Reverse Gear Shift Lever Bolts

   Courtesy of SUZUKI OF AMERICA CORP.
5. Clean mating surfaces of both right and left cases, apply sealant to right case (1) as shown in the figure by such amount that its section is 1.5 mm (0.059 in.) in diameter then mate it with left case (2).

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

6. Tighten case bolts (3) to specified torque.

   Tightening torque 

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

   Fig 4: Identifying Transaxle Case Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
7. Install back up lamp switch. See BACK UP LAMP SWITCH REMOVAL AND INSTALLATION .