Input Shaft Inspection - Suzuki Grand Vitara Manual

Input Shaft Inspection

• Check clearance "a" between synchronizer ring (2)
and gear (1), key slot width "b" in synchronizer ring
and each chamfered tooth of gear and synchronizer
ring and replace with new one, if necessary. Also,
check gear tooth.
Clearance "a" between synchronizer ring and
gear (Input shaft) (3rd and 4th)
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width "b" (3rd and 4th synchronizer ring)
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)
• Measure width of high speed gear shift fork end "a"
and groove width of high speed synchronizer sleeve
"b", 5th & reverse gear shift fork end "a" and groove
width of 5th speed synchronizer sleeve "b" and then
calculate clearance "c" as follows:
Clearance "c" = "b"
If clearance exceeds limit, replace fork bush (1) and
sleeve.
Clearance "c" between fork and sleeve for high
speed and 5th speed
Standard: 0.3 – 0.5 mm (0.012 – 0.020 in.)
Limit: 1.0 mm (0.039 in.)
1
"a"
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– "a"
"b"
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Manual Transmission/Transaxle:
• Check diameter of input shaft (1) and needle bush (2)
as shown in the figure. If measured value is out of
specification, replace input shaft and/or bush.
Input shaft and needle bush specifications
(diameter)
Measuring
portion
"a"
"b"
"c"
"d"
"e"
"f"
"g"
"h"
1
"a"
• Using "V" blocks (1) and dial gauge (2), check runout.
If runout exceeds limit below, replace input shaft (3).
Input shaft runout
Limit: 0.02 mm (0.0008 in.)
5B-22
Standard
30.002 – 30.015 mm
(1.1812 – 1.1816 in.)
34.950 – 34.991 mm
(1.3760 – 1.3775 in.)
30.959 – 30.975 mm
(1.2189 – 1.2194 in.)
27.987 – 28.000 mm
(1.1018 – 1.1023 in.)
27.967 – 27.980 mm
(1.1011 – 1.1015 in.)
19.975 – 19.991 mm
(0.7865 – 0.7870 in.)
28.000 – 28.013 mm
(1.1024 – 1.1028 in.)
34.975 – 34.991 mm
(1.3770 – 1.3775 in.)
"g" "h"
2
"b"
"d"
"f"
"e"
"c"
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2
3
1
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