5B
Manual Transmission Assembly Disassembly and Reassembly
Disassembly
1) Remove clutch release bearing and release fork referring to Clutch Cover, Clutch Disc, Flywheel and Release Bearings Removal and Installation:M13A Model .
2) Remove gear shift lever case assembly referring to Gear Shift Lever Case Assembly Removal and Installation:M13A Model .
3) Remove extension case.
4) Remove output shaft assembly.
5) Remove reverse shaft bolt (1) and back up lamp switch (2).
6) Remove gear shift locating bolts (1), then take out locating springs and gear shift shaft balls.
7) Remove rear to front case bolts (2), then separate rear case from front case tapping front case flange with plastic hammer.
8) Remove reverse shaft assembly.
9) Remove 5th gear shift inverse lever (1).
10) Remove low speed gear shift shaft (2) and input shaft needle bearing.
11) Open input shaft front bearing snap ring (1) using snap ring pliers and remove input shaft assembly (2), countershaft assembly (3), high speed gear shift fork (4), 5th & reverse gear shift fork (5) and low speed gear shift fork (6) as assembly from front case (7) tapping input shaft end by plastic hammer lightly.
Reassembly
CAUTION:
Take care not to damage oil seal lip by input shaft, or oil leakage may take place.
1) Open input shaft front bearing snap ring (1) using snap ring pliers and assemble input shaft assembly (2), countershaft assembly (3), high speed gear shift fork (4), 5th & reverse gear shift fork (5) and low speed gear shift fork (6), then install them all together into front case (7) while installing input shaft front bearing snap ring (1) using special tool.
2) Install low speed gear shift shaft (1) and 5th gear shift inverse lever (2) and tighten with bolt (3) to which thread lock cement has been applied.
“A” : Thread lock cement 99000–32110 ( Thread Lock Cement Super 1322 )
Tightening torque
5th gear shift inverse lever bolt ( a ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
3) 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.
C: Chamfered side
4) Clean mating surfaces of both front and rear cases, and uniformly apply sealant to front case (3) as shown in figure.
“A” : Sealant 99000–31260 ( SUZUKI Bond No.1217G )
5) Tighten case bolts (1) to specified torque.
Tightening torque
Transmission case bolt ( b ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
6) Apply thread lock cement to reverse shaft bolt (2), and tighten it.
“B” : Thread lock cement 99000–32110 ( Thread Lock Cement Super 1322 )
Tightening torque
Reverse shaft bolt ( a ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
7) Install back up lamp switch (4) referring to Back Up Lamp Switch Removal and Installation:M13A Model .
8) Apply grease to gear shift shaft balls (1) and locating springs (long) (2), locating spring (short) (3) then install them.
Apply thread lock cement to gear shift locating bolts (4), and then tighten them.
“A” : Grease 99000–25010 ( SUZUKI Super Grease A )
“B” : Thread lock cement 99000–32110 ( Thread Lock Cement Super 1322 )
Tightening torque
Gear shift locating bolt ( a ): 13 N·m ( 1.3 kg-m, 9.0 lb-ft)
9) Install output shaft into rear case.
10) Select a countershaft shim as follows.
a) Measure depth “a” from mating surface of extension case (1) to face processed for installation of countershaft rear bearing (2) using vernier caliper.
b) Measure height “b” from mating surface of rear case (3) to countershaft rear bearing (2) using vernier caliper.
c) Calculate “a” – “b”, and select a shim according to the following table.
Countershaft shim selection table
Clearance “a” – “b” Thickness of countershaft shim
1.25 – 1.34 mm (0.049 – 0.052 in.) 1.00 mm (0.039 in.)
1.35 – 1.44 mm (0.053 – 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.)
11) Install selected countershaft shim to extension case.
12) Clean mating surface of both rear case (1) and extension case, and uniformly apply sealant to rear case as shown in figure.
“A” : Sealant 99000–31260 ( SUZUKI Bond No.1217G )
13) Tighten case bolts (2) to specified torque.
Tightening torque
Extension case bolt ( a ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
14) Install gear shift lever case assembly (3) referring to Gear Shift Lever Case Assembly Removal and Installation:M13A Model .
15) Install clutch release bearing and release fork referring to Clutch Cover, Clutch Disc, Flywheel and Release Bearings Removal and Installation:M13A Model .