Synchronizer Parts Inspection; Gear Shift Shaft Components - Suzuki Swift Sport 2004 Service & Repair Manual

Synchronizer Parts Inspection

Check clearance "a" between synchronizer ring (2) and
gear (1), each chamfered tooth of gear, synchronizer
ring and sleeve, then determine parts replacement.
Clearance "a" between synchronizer ring and gear
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)

Gear Shift Shaft Components

7
5
1. Low speed gear shift shaft
2. High speed gear shift shaft
3. 5th & reverse gear shift shaft
4. 5th & reverse gear shift guide shaft
S7RS0B5206021
I2RH01520048-01
6
(a)
3
4
5. Reverse gear shift arm
6. 5th gear shift fork
7. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
8. Shift fork bolt
: Apply thread lock 99000-32110 to bolt thread.
Manual Transmission/Transaxle:
Put the 2nd gear synchronizer outer ring (1), inner ring
(3) and the cone (2) together and then measure the step
difference between the outer ring and the inner ring. And
also check each chamfered tooth of gear and
synchronizer ring and replace with new one, if
necessary. Also, check gear tooth.
Difference "b" between synchronizer outer ring and
inner ring
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)
8 (b)
7
(a)
1
5B-31
I2RH01520059-01
S7RS0B5206022
7
(a)
2
I4RS0A520015-01
: 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)