Gear Shift Shafts; Extension Case Bush; Main Shaft And Input Shaft - Suzuki Samurai 1986 Service Manual

Gear Shift Shafts

Check the part of shaft as indicated in below
figure for uneven wear. Replace shaft if uneven
wear is noted.
Fig. 13-40

Extension Case Bush

Check bush press-fitted in extension case for
wear by measuring radial clearance between
bush bore and sliding yoke. If sliding yoke
rattles in bush because of advanced wear it will
cause propeller shaft to rattle. For this reason,
an extension case found to allow its sliding
yoke to rattle in excess of service limit must be
replaced; replacement of bush alone is not
permissible.
Rattle of Standard
sliding yoke
0.025 - 0.089 mm
in extension
(0.0010 - 0.0035 in.)
case bush
13-6. IMPORTANT STEPS IN
NOTE:
l
l
l

Main Shaft and Input Shaft

Install each parts by reversing respective removal
procedures. Be careful for installing direction of
each washer, gear, synchronizer hub and sleeve.
Refer to figure below. Make sure to install each
ball on main shaft.
1. High speed synchronizer
2. High speed synchronizer
0.2 mm
(0.0078 in.)
3. 3rdgear
4. 2ndgear
I
5. Low speed synchronizer
6. Low speed synchronizer
7. Lowgear
Fig. 13-4 1
INSTALLATION
Before installation, wash each part and apply
specified gear oil to sliding faces of bearing
and gear.
Use new circlips on shaft for reinstallation.
Don't reuse used circlips.
Tighten each fastening bolt and nut according
to specified torque data listed on the last
page of this section.
5 17
hub
10. Reverse gear
11. Reverse synchronizer
sleeve
12. Reverse synchronizer
13. 5th gear
hub
14. 5th gear washer
15. Circlip
sleeve
16. Main shaft
16
6. Washer
9. Ball
hub
sleeve
17. Spring
13-15