Suzuki Grand Vitara Manual page 161

14) Install output shaft assembly into rear case.
15) Select a countershaft shim and output shaft shim as
follows.
a) Measure depth "a" from mating surface of
adapter case (1) to face processed for
installation of countershaft rear bearing (2) and
measure depth "c" from mating surface of
adapter case to face processed for installation of
output shaft rear bearing (5) using vernier
caliper.
b) Measure height "b" from mating surface of rear
case (3) to countershaft rear bearing (2) and "d"
from mating surface of rear case (3) to output
shaft bearing (6) using vernier caliper.
c) Calculate "a" – "b" and "c" – "d", and select a
shim according to the following table.
Countershaft shim selection table
Clearance "a" – "b"
1.15 – 1.24 mm
(0.046 – 0.048 in.)
1.25 – 1.34 mm
(0.050 – 0.052 in.)
1.35 – 1.44 mm
(0.054 – 0.056 in.)
1.45 – 1.54 mm
(0.057 – 0.060 in.)
1.55 – 1.64 mm
(0.061 – 0.064 in.)
1.65 – 1.74 mm
(0.065 – 0.068 in.)
1.75 – 1.84 mm
(0.069 – 0.072 in.)
1.85 – 1.94 mm
(0.073 – 0.076 in.)
1.95 – 2.04 mm
(0.077 – 0.080 in.)
2.05 – 2.14 mm
(0.081 – 0.084 in.)
2.15 – 2.24 mm
(0.085 – 0.088 in.)
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Thickness of
countershaft shim
0.90 mm (0.035 in.)
1.00 mm (0.039 in.)
1.10 mm (0.043 in.)
1.20 mm (0.047 in.)
1.30 mm (0.051 in.)
1.40 mm (0.055 in.)
1.50 mm (0.059 in.)
1.60 mm (0.063 in.)
1.70 mm (0.067 in.)
1.80 mm (0.071 in.)
1.90 (0.90 + 1.00) mm
(0.075 (0.035 + 0.039) in.)
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Manual Transmission/Transaxle:
Output shaft shim selection table
Clearance "c" – "d"
0 – 0.09 mm (0 – 0.04 in.)
0.1 – 0.19 mm
(0.004 – 0.007 in.)
0.2 – 0.29 mm
(0.008 – 0.011 in.)
0.3 – 0.39 mm
(0.012 – 0.015 in.)
0.4 – 0.49 mm
(0.016 – 0.019 in.)
0.5 – 0.59 mm
(0.020 – 0.023 in.)
0.6 – 0.69 mm
(0.024 – 0.027 in.)
0.7 – 0.79 mm
(0.028 – 0.031 in.)
"d"
"b"
3
5
"c"
"a"
2
16) Install selected countershaft shim and output shaft
shim to adapter case.
17) Clean mating surface of both rear case (1) and
adapter case, and uniformly apply sealant to rear
case as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter, and then
mate it with adapter case.
"A": Sealant 99000–31260 (SUZUKI Bond
No.1217G)
5B-20
Thickness of
countershaft shim
—
0.1 mm (0.004 in.)
0.2 mm (0.008 in.)
0.3 mm (0.012 in.)
0.4 mm (0.016 in.)
0.5 (0.2 + 0.3) mm
(0.020 (0.008 + 0.012) in.)
0.6 (0.2 + 0.4) mm
(0.024 (0.008 + 0.016) in.)
0.7 (0.3 + 0.4) mm
(0.028 (0.012 + 0.016) in.)
6
4
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