Manual Transaxle - Suzuki WagonR+ RB310 Service Manual

WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under
"General Description" in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-
vice Precautions" under "On-Vehicle Service" in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
"LOCK" position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
General Description......................................7A2-2
Manual Transaxle Construction and
Servicing .....................................................7A2-2
Transaxle for 2wd Model .............................7A2-3
Transaxle for 4wd Model .............................7A2-4
Diagnosis.......................................................7A2-5
Manual Transaxle Symptom Diagnosis.......7A2-5
On-Vehicle Service........................................7A2-6
Manual Transaxle Oil Change.....................7A2-6
Differential Side Oil Seal Replacement .......7A2-6
Gear Shift Control Lever and Cable
Components................................................7A2-8
Gear Shift Control Lever and Cable
Removal and Installation.............................7A2-9
Gear Shift Control Lever and Cable
Adjustment ................................................7A2-10
Vehicle Speed Sensor (VSS) Removal
and Installation ..........................................7A2-11
Back Up Lamp Switch Removal and
Installation .................................................7A2-12
Back Up Lamp Switch Inspection..............7A2-12
Unit Repair Overhaul ..................................7A2-13
Transaxle Unit Components......................7A2-13
Transaxle Unit Dismounting and
Remounting...............................................7A2-14
Transaxle Case Components....................7A2-16
SECTION 7A2

MANUAL TRANSAXLE

(M13 ENGINE MODEL)
CONTENTS
MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-1
Gear Shift and Select Shaft Assembly
Components.............................................. 7A2-17
Gear Shift and Select Shaft Assembly
Removal and Installation........................... 7A2-18
Gear Shift and Select Shaft Disassembly
and Assembly ........................................... 7A2-19
Fifth Gear Disassembly and Assembly ..... 7A2-19
Gear Shift Shaft, Input Shaft and Counter
Shaft Removal and Installation ................. 7A2-24
Transaxle Case Disassembly and
Assembly .................................................. 7A2-28
Input & Counter Shaft Components .......... 7A2-30
Input Shaft Disassembly and Assembly.... 7A2-31
Counter Shaft Disassembly and
Assembly .................................................. 7A2-34
Gear Shift Shaft Components ................... 7A2-38
High Speed and Low Speed Gear Shift
Shafts Inspection ...................................... 7A2-39
5th & Reverse Gear Shift Shafts
Disassembly and Assembly ...................... 7A2-39
Differential Components ........................... 7A2-40
Differential Disassembly and Assembly.... 7A2-41
Differential Adjustment.............................. 7A2-42
Tightening Torque Specification...............7A2-44
Required Service Material ..........................7A2-45
Special Tool.................................................7A2-45
7A2