Manual Transmission Unit Reassembly - Suzuki Grand Vitara Manual

15) Remove input shaft assembly (1), countershaft
assembly (2), high speed gear shift fork (3) and low
speed gear shift fork (4) as assembly from front case
(5) tapping input shaft end by plastic hammer lightly.

Manual Transmission Unit Reassembly

1) Assemble input shaft assembly (1), countershaft
assembly (2), high speed gear shift fork (3) and low
speed gear shift fork (4), then install them all
together into front case (5).
CAUTION
!
Take care not to damage oil seal lip by input
shaft, or oil leakage may take place.
2) Install input shaft front bearing snap ring (1) using
special tool.
Special tool
(A): 09900–06106
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4
2
1
5
3
I5JB0A520039-01
S5JB0A5206013
4
2
1
5
3
I5JB0A520039-01
(A)
1
I5JB0A520040-01
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Manual Transmission/Transaxle:
3) Install low speed gear shift shaft (1) and low gear
shift inverse lever (2) and tighten with new bolt (3).
Tightening torque
Low gear shift inverse lever bolt (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
2
4) Fit 5th & reverse gear shift fork (1) to 5th speed
synchronizer sleeve (2), and install them into input
shaft and front case in specified direction as shown
in figure.
2
1
A: Chamfered side
5) Set reverse idler gear (1), reverse gear shift lever (2)
and reverse gear shaft washer (4), insert reverse
gear shaft (3) into case through idler gear and then
align hole "B" in shaft with protrusion "A" in case.
3
2
5B-18
1
3, (a)
I5JB0A520041-02
A
I5JB0A520042-01
"B"
4
1
"A"
I5JB0A520043-01