Countershaft Disassembly and Reassembly: Reassembly

Reference: COUNTERSHAFT INSPECTION 

Reference: GEAR SHIFT SHAFT AND FORK INSPECTION 

1. Fit low speed synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
   NOTE: No specific direction is assigned to low speed synchronizer hub and each key but it is assigned as assembly.
   Fig 1: Identifying Synchronizer Sleeve To Hub And Keys

   Courtesy of SUZUKI OF AMERICA CORP.
2. Install reverse gear (1) to countershaft (2) using puller (3) and hydraulic press.
   Fig 2: Installing Reverse Gear To Countershaft Using Puller

   Courtesy of SUZUKI OF AMERICA CORP.
3. Install 1st gear spacer (1) using special tool and hydraulic press.

   Special Tool 

   1. 09940-54910 
   Fig 3: Installing 1st Gear Spacer Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install 1st gear needle bearing and apply transaxle oil to it, and then install 1st gear synchronizer inner ring (2), 1st gear synchronizer center cone (3), 1st gear synchronizer outer ring (4) and 1st gear (1) to countershaft.
   NOTE: Make sure claws on 1st gear synchronizer center cone fit into the holes on 1st gear.
   Fig 4: Identifying 1st Gear Synchronizer Center Cone, 1st Gear Synchronizer Inner Ring And 1st Gear Synchronizer Outer Ring

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install low speed sleeve & hub assembly (1) using special tool and hydraulic press.
   NOTE:

   • Support lower speed synchronizer hub with special tool as shown in figure.
   • Make sure that synchronizer ring key slots are aligned with keys (5) while press-fitting sleeve & hub assembly.
   • Check free rotation of 1st gear (3) after press-fitting sleeve & hub assembly.

   Special Tool 

   1. 09944-77030 
   Fig 5: Installing Low Speed Sleeve & Hub Assembly Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install 2nd gear spacer (1) using special tool and hydraulic press.

   Special Tool 

   1. 09945-55410 
   Fig 6: Installing 2nd Gear Spacer Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
7. Install 3rd gear (5), 2nd gear (1), 2nd gear synchronizer inner ring (2), 2nd gear synchronizer center cone (3) and 2nd gear synchronizer outer ring (4) to countershaft using special tool and hydraulic press.
   NOTE: Make sure claws on 2nd gear synchronizer center cone fit into the holes on 2nd gear.

   Special Tool 

   1. 09944-77030 
   Fig 7: Identifying 2nd Gear Synchronizer Center Cone, 2nd Gear Synchronizer Inner Ring And 2nd Gear Synchronizer Outer Ring

   Courtesy of SUZUKI OF AMERICA CORP.
8. Select new circlip (1) that makes thrust clearance "a" of bearing 0.15 mm (0.0059 in) or less and install it.
   Fig 8: Identifying Circlip

   Courtesy of SUZUKI OF AMERICA CORP.

   Available circlip thickness 

   CIRCLIP THICKNESS SPECIFICATION
   
   

   Clearance "b"	Select circlip
   2.000 - 2.100 mm (0.0788 - 0.0826 in.)	2.00 mm (0.0788 in.)
   2.100 - 2.200 mm (0.0826 - 0.0866 in.)	2.10 mm (0.0826 in.)
   2.200 - 2.300 mm (0.0866 - 0.0905 in.)	2.20 mm (0.0866 in.)
   2.300 - 2.400 mm (0.0905 - 0.0944 in.)	2.30 mm (0.0905 in.)
   2.400 - 2.500 mm (0.0944 - 0.0984 in.)	2.40 mm (0.0944 in.)
   2.500 - 2.600 mm (0.0984 - 0.1023 in.)	2.50 mm (0.0984 in.)

9. Install 4th gear (1) using puller and hydraulic press.
   Fig 9: Identifying 4th Gear Using Puller

   Courtesy of SUZUKI OF AMERICA CORP.
10. Install 5th gear by the same procedure at step  7).
11. Install 6th gear (1) and 5th gear spacer (2) using special tool and hydraulic press.

    Special Tool 

    1. 09945-55410 
    Fig 10: Identifying 6th Gear And 5th Gear Spacer

    Courtesy of SUZUKI OF AMERICA CORP.
12. Install countershaft left bearing (1) and washer using special tool and hydraulic press.

    Special Tool 

    1. 09913-84510 
    Fig 11: Identifying Countershaft Left Bearing And Washer

    Courtesy of SUZUKI OF AMERICA CORP.
13. Install countershaft right bearing (1) using special tool and hydraulic press.

    Special Tool 

    1. 09913-84510 
    Fig 12: Identifying Countershaft Right Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
14. Select new circlip (1) that makes thrust clearance "a" of bearing 0.1 mm (0.0039 in) or less and install it.
    Fig 13: Identifying Circlip

    Courtesy of SUZUKI OF AMERICA CORP.

    Available circlip thickness 

    CIRCLIP THICKNESS SPECIFICATION
    
    

    Clearance "b"	Select circlip
    1.810 - 1.860 mm (0.0713 - 0.0732 in.)	1.81 mm (0.0713 in.)
    1.860 - 1.910 mm (0.0732 - 0.0751 in.)	1.86 mm (0.0732 in.)
    1.910 - 1.960 mm (0.0751 - 0.0771 in.)	1.91 mm (0.0751 in.)
    1.960 - 2.010 mm (0.0771 - 0.0791 in.)	1.96 mm (0.0771 in.)
    2.010 - 2.060 mm (0.0791 - 0.0811 in.)	2.01 mm (0.0791 in.)
    2.060 - 2.100 mm (0.0811 - 0.0826 in.)	2.06 mm (0.0811 in.)
    2.100 - 2.130 mm (0.0826 - 0.0838 in.)	2.10 mm (0.0826 in.)
    2.130 - 2.160 mm (0.0838 - 0.0850 in.)	2.13 mm (0.0838 in.)
    2.160 - 2.190 mm (0.0850 - 0.0862 in.)	2.16 mm (0.0850 in.)
    2.190 - 2.220 mm (0.0862 - 0.0874 in.)	2.19 mm (0.0862 in.)
    2.220 - 2.250 mm (0.0874 - 0.0885 in.)	2.22 mm (0.0874 in.)
    2.250 - 2.280 mm (0.0885 - 0.0897 in.)	2.25 mm (0.0885 in.)
    2.280 - 2.310 mm (0.0897 - 0.0909 in.)	2.28 mm (0.0897 in.)