5B
Manual Transmission Assembly Disassembly and Assembly
Disassembly
1) Remove clutch release bearing and release fork referring to Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation:K9K Model .
2) Remove gear shift lever case assembly referring to Gear Shift Lever Case Assembly Removal and Installation:K9K 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 oil gutter.
9) Remove reverse shaft assembly (1).
10) Remove 5th gear shift inverse lever (4).
11) Remove low speed gear shift shaft (2) and 5th & reverse gear shift fork (3).
12) Remove input shaft needle bearing, 5th speed synchronizer ring, 5th speed synchronizer levers and 5th speed synchronizer sleeve.
13) Remove input shaft front bearing circlip (1) from case using special tool.
Special Tool
(A) : 09900–06106
14) Remove input shaft assembly (1), countershaft assembly (2), high speed gear shift fork (3) and low speed gear shift fork (4) as assembly from front case (5) tapping input shaft end by plastic hammer lightly.
Assembly
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.
2) Install input shaft front bearing circlip (1) using special tool.
Special Tool
(A) : 09900–06106
3) 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)
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 the figure.
A: Chamfered side
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.
6) Install oil gutter
7) Install 5th speed synchronizer levers and 5th speed synchronizer ring as follows.
a) Fit 5th speed synchronizer levers (1) to hub (2) aligning protrusion “A” of 5th speed synchronizer levers with groove of hub.
b) Install synchronizer ring (1) to hub (2) in specified direction as shown in the figure.
8) Clean mating surfaces of both front and rear cases, and uniformly apply sealant to front case (3) as shown in the figure.
“A” : Sealant 99000–31260 ( SUZUKI Bond No.1217G )
9) Tighten case bolts (1) to specified torque.
Tightening torque
Transmission case bolt ( b ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
10) 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)
11) Install back up lamp switch (4) referring to Back Up Lamp Switch Removal and Installation:K9K Model .
12) Apply grease to gear shift shaft balls (1) and locating springs (2), then install them.
Apply thread lock cement to gear shift locating bolts (3), 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 ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
13) Install output shaft into rear case.
14) Select a countershaft shim and output shaft shim as follows.
a) Measure depth “a” from mating surface of extension case (1) to face processed for installation of countershaft rear bearing (2) and measure depth “c” from mating surface of extension case to face processed for installation of output shaft rear bearing (4) using vernier caliper
b) Measure height “b” from mating surface of rear case (3) to countershaft rear bearing (2) and measure height “d” from mating surface of rear case (3) to output shaft rear bearing (4) using vernier caliper.
c) 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
(0.045 – 0.048 in.)
0.90 mm (0.035 in.)
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.)
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 countershaft shim
0.1 – 0.19 mm
(0.004 – 0.007 in.)
0.2 – 0.29 mm
(0.008 – 0.011 in.)
0.10 mm (0.004 in.)
0.3 – 0.39 mm
(0.012 – 0.015 in.)
0.20 mm (0.008 in.)
0.4 – 0.49 mm
(0.016 – 0.019 in.)
0.30 mm (0.012 in.)
0.5 – 0.59 mm
(0.020 – 0.023 in.)
0.40 mm (0.016 in.)
0.6 – 0.69 mm
(0.024 – 0.027 in.)
0.50 mm (0.020 in.)
0.7 – 0.79 mm
(0.028 – 0.031 in.)
0.60 mm (0.024 in.)
0.8 – 0.89 mm
(0.032 – 0.035 in.)
0.70 mm (0.028 in.)
0.9 – 0.99 mm
(0.036 – 0.038 in.)
0.80 mm (0.031 in.)
1.0 – 1.09 mm
(0.040 – 0.042 in.)
0.90 mm (0.035 in.)
1.1 – 1.19 mm
(0.044 – 0.046 in.)
1.00 mm (0.039 in.)
1.2 – 1.29 mm
(0.048 – 0.050 in.)
1.10 mm (0.043 in.)
1.3 – 1.39 mm
(0.052 – 0.054 in.)
1.20 mm (0.047 in.)
15) Install selected countershaft shim and output shaft shim to extension case.
16) Clean mating surface of both rear case (1) and extension case, and uniformly apply sealant to rear case as shown in the figure.
“A” : Sealant 99000–31260 ( SUZUKI Bond No.1217G )
17) Tighten case bolts (2) to specified torque.
Tightening torque
Extension case bolt ( a ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
18) Install gear shift lever case assembly (3) referring to Gear Shift Lever Case Assembly Removal and Installation:K9K Model .
19) Install clutch release bearing and release fork referring to Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation:K9K Model .