Suzuki Grand Vitara XL-7 Service Manual page 385

b) Align protrusion of synchronizer outer ring (2) into groove of
synchronizer inner ring (1), then install synchronizer outer
ring to 3rd gear (3) as shown in the figure.
c) Align protrusion of synchronizer outer ring (1) into slot of syn-
chronizer hub (2), and then attach high speed synchronizer
sleeve and hub assembly to 3rd gear (3).
3) Install needle bearing (2) to main shaft (1) and press fit 3rd gear
high speed synchronizer sleeve and hub assembly (3), which
was assembled in step "a" through "c" , to main shaft (1) using
special tool.
Special tool
(A): 09940-53111
4) Select circlip (1) that will make thrust clearance of clutch hub 0.1
mm (0.0039 in) or less and install it.
Circlip thickness specification:
ID mark
C – 1
D
11
12
13
14
15
Special tool
(B): 09900-06107
5) After installing circlip, check that 3rd gear turns lightly.
MANUAL TRANSMISSION 7A2-37
Circlip thickness
1.75 – 1.80 mm (0.0689 – 0.0708 in.)
1.80 – 1.85 mm (0.0708 – 0.0728 in.)
1.86 – 1.91 mm (0.0729 – 0.0751 in.)
1.92 – 1.97 mm (0.0752 – 0.0775 in.)
1.98 – 2.03 mm (0.0776 – 0.0799 in.)
2.04 – 2.09 mm (0.0800 – 0.0822 in.)
2.10 – 2.15 mm (0.0823 – 0.0846 in.)