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).
   NOTE: Oil leaks will occur if the oil seal lip is damaged.
   Be careful not to damage the oil seal lip when inserting the input shaft into the front case.
   Fig 1: Identifying Input Shaft, Countershaft Assembly, High And Low Speed Gear Shift Fork, And Front Case

   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 Using Special Tool

   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).
   NOTE: The inverse lever bolt is pre-coated with adhesive. If the bolt is reused, it may work loose.
   Never reuse the inverse lever bolt.

   Tightening torque 

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

   Fig 3: Low Speed Gear Shift Shaft, Shift Inverse Lever And Bolt With Torque Specifications

   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 Speed Synchronizer Sleeve, 5th And Reverse Gear Shift Fork

   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, Reverse Gear Shaft Washer, Alignment Hole And Protrusion

   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, Hub And Alignment Protrusion

      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: Identifying Front Case Sealant Applying Area

   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 kgf-m, 17.0 lbf-ft) 

11. Install new reverse shaft bolt (2) and new washer, and tighten it to specified torque.
    NOTE: The reverse shaft bolt is pre-coated with adhesive. If the bolt is reused, it may work loose.
    Never reuse the reverse shaft bolt.

    Tightening torque 

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

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

    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.

    NOTE: The shift locating bolt is pre-coated with adhesive. If the bolt is reused, it may work loose.
    Never reuse the shift locating bolt.

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

    Tightening torque 

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

    Fig 10: Gear Shift Locating Bolt Sealant Applying Area With Torque Specifications

    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
       
       

       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
       
       

       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: Identifying Countershaft Shim And Output Shaft Installation Dimension

       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 kgf-m, 17.0 lbf-ft) 

    Fig 12: Rear Case To Adapter Case Mounting Bolts With Torque Specifications

    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 .