Output Shaft Disassembly And Assembly; Output Shaft Inspection - Suzuki Grand Vitara Manual

5B-29 Manual Transmission/Transaxle:
• Check oil clearance between reverse idle gear (2) and
shaft (1) measuring inside diameter "a" of gear and
diameter "b" of shaft and calculate as follows:
Clearance "c" = "b"
If clearance exceeds limit, replace gear and shaft.
Oil clearance "c" between reverse idle gear and
shaft
Standard: 0.016 – 0.045 mm (0.0006 – 0.0018 in.)
Limit: 0.13 mm (0.005 in.)
• Check clearance between reverse idle gear (2) and
lever (1) of reverse gear shift link.
If clearance exceeds limit, replace gear and lever.
Clearance between reverse idle gear and lever
Standard: 0.05 mm – 0.35 mm (0.002 – 0.014 in.)
Limit: 0.5 mm (0.020 in.)
2

Output Shaft Disassembly and Assembly

Disassembly
1) Remove output shaft rear snap ring.
2) Apply bearing puller to output shaft front bearing (1),
and drive out output shaft front bearing, output shaft
gear (2) and output shaft rear bearing (3) all at once
from output shaft using press.
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– "a"
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Assembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) Put front bearing (1) onto output shaft facing groove
(4) side to output shaft gear (2) and drive in output
shaft front bearing, output shaft gear and output
shaft rear bearing (3) all together using special tool
and hammer.
Special tool
(A): 09940–51710
(A)
3
2
1
3) Install new output shaft rear snap ring.

Output Shaft Inspection

Check clearance "a" between ring (2) and output shaft
(1), each chamfered teeth of gear, ring and sleeve, then
determine parts replacement.
Clearance between synchronizer ring and output
shaft
Standard "a": 1.0 - 1.4 mm (0.040 - 0.055 in.)
Service limit "a": 0.5 mm (0.020 in.)
2
"a"
1
3
2
1
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