Fifth Gear Disassembly And Assembly - Suzuki Swift Sport 2004 Service & Repair Manual

5B-14 Manual Transmission/Transaxle:
11. Sensor cap
12. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
13. Left case plate bolts
: Apply thread lock 99000-32110 to all around thread part of bolt.
14. Sensor cap bolt
15. Side cover bolts
16. Transaxle case bolts
17. 5th speed synchronizer ring
18. 5th speed synchronizer lever
19. 5th speed synchronizer sleeve & hub
20. Circlip
21. Bearing set shim
22. Countershaft 5th gear
23. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.

Fifth Gear Disassembly and Assembly

Disassembly
1) Remove cover bolts and take off transaxle side cover
(1).
CAUTION
!
Care should be taken not to distort side cover
when it is removed from left case.
2) Using snap ring pliers, remove circlip (1).
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchronizer levers, synchronizer
ring and input shaft 5th gear (5) all together. Use
gear puller for removal if spline fitting of hub is tight.
3
2
1
5
S7RS0B5206014
I4RS0A520027-01
4
I4RS0A520028-01
34. Washer
35. Side bearing retainer
36. O-ring
37. Oil seal
: Apply grease 99000-25011 to oil seal lip.
38. Outer race
39. Breather hose
40. Side bearing retainer bolt
: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
: 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
: 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
: Do not reuse.
: Apply transaxle oil.
5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
1
6) Remove input shaft 5th gear, needle bearing and
then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
(A)
2
I3RM0B521014-01
I4RS0A520041-01