Suzuki Liana RH413 Service Manual page 739

NOTE
Correct tool tips to be flat to facilitate
removal of circlip.
Special tool
(A): 09900–06107
2. Low speed synchronizer sleeve
5) Apply puller (3) to 1st gear (2) and drive out low
speed synchronizer sleeve & hub assembly (1) with
1st gear by using hydraulic press.
CAUTION
!
To avoid gear tooth from damage, support it
at flat side of bearing puller.
6) Disassemble synchronizer sleeve & hub assembly.
7) Take out 1st gear needle bearing of resin cage type
from shaft.
8) Remove right bearing cone (2) by using puller (3),
metal stick (1) and hydraulic press.
Assembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) If synchronizer parts need to be repaired, check
clearance "a" between ring (2) and gear (1), each
chamfered tooth of gear, ring and sleeve, then
determine parts replacement.
Clearance "a" between synchronizer ring and
gear
Standard: 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit: 0.5 mm (0.019 in.)
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3) Put the 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 between synchronizer outer ring and
inner ring
Standard "b": 0.95 – 1.25 mm (0.036 – 0.048 in.)
Service limit "b": 0.5 mm (0.019 in.)
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4) To ensure lubrication of countershaft (1), air blow oil
holes (2) and make sure that they are free from any
obstruction.
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Manual Transmission/Transaxle: 5B-30
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