Suzuki Swift Sport 2004 Service & Repair Manual page 843

5) Apply bearing puller (3) to 1st gear (2) and drive out
low speed synchronizer sleeve & hub assembly (1)
with 1st gear using hydraulic press.
CAUTION
!
To avoid gear tooth from being damaged,
support it at flat side of bearing puller.
6) Disassemble low speed synchronizer sleeve & hub
assembly.
7) Take out 1st gear needle bearing from shaft.
8) Remove right bearing cone (2) using bearing puller
(3), metal stick (1) and hydraulic press.
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) To ensure lubrication of countershaft (1), air blow oil
holes (2) and make sure that they are free from any
obstruction.
3) Fit low speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to each
key but it is assigned as sleeve & hub
assembly.
• Size of low speed synchronizer keys and
springs are the largest compared with
those of high speed and 5th speed ones.
Synchronizer key installation position
A = B
I2RH01520057-01
I2RH01520058-01
[A]: 1st gear side
C: Key way
4) Install right bearing cone (1) to countershaft (2) using
special tool and hammer.
Special tool
(A): 09923–78210
I2RH01520060-01
Manual Transmission/Transaxle:
D: Short flange
5B-29
I3RM0A520051-01
I2RH01520062-01