Locating Spring Inspection; Input Shaft Disassembly - Suzuki Grand Vitara Manual

5B-21 Manual Transmission/Transaxle:
18) Install rear case to adapter case. Tighten case bolts
(2) to specified torque.
Tightening torque
Adapter case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
2, (a)
2, (a)
19) Install transfer assembly to transmission assembly.
Tighten transfer fastening bolts to specified torque
referring to "Transfer Assembly Components: Motor-
Shift Type (Transfer with Shift Actuator) in Section
3C" or "Transfer Assembly Components: Non-Shift
Type (Transfer without Shift Actuator) in Section 3C".
20) Install gear shift control lever rear case assembly
and gear shift lever front case assembly referring to
"Gear Shift Control Lever Rear Case Assembly
Removal and Installation: " and "Gear Shift Lever
Front Case Assembly Removal and Installation: ".
21) Install clutch operating cylinder assembly to
transmission front case referring to "Clutch
Operating Cylinder Assembly Removal and
Installation: in Section 5C".

Locating Spring Inspection

Check locating springs for deterioration and replace with
new ones if necessary.
Locating spring free length
Standard: 44.6 mm (1.756 in.)
Service limit: 40.1 mm (1.579 in.)

Input Shaft Disassembly

1) Remove snap ring.
2) Remove input shaft front bearing (1) using bearing
puller and hydraulic press.
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1
"A"
2, (a)
2, (a)
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3) Remove input shaft union.
4) Hold hatched area (5) of input shaft assembly (1)
with "V" blocks (4) on vise (2) or the like to stop
rotation of shaft, undo caulking and input shaft 5th
hub nut (3).
CAUTION
!
Do not hold spline, gear teeth or abrasived
surface of shaft with vise through "V" blocks
or the like, otherwise shaft components may
be damaged.
1
2
4
5) Apply bearing puller to 4th gear (1), and drive out 5th
speed synchronizer hub (2), 3rd gear (3), high speed
gear needle bearings, 3rd gear bush, high speed
synchronizer assembly (4) and 4th gear all at once
from input shaft using metal stick (5) and press.
CAUTION
!
To avoid gear teeth from being damaged,
support 4th gear at flat side of bearing puller.
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4
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3
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