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MANUAL TRANSAXLE (M15 ENGINE MODEL)
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System :
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under
"General Description" in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-
vice Precautions" under "On-Vehicle Service" in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
"LOCK" position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
General Description ......................................7A2-2
Manual Transaxle Construction
and Servicing .............................................. 7A2-2
Construction Diagram of 2WD Transaxle.... 7A2-3
Construction Diagram of 4WD Transaxle.... 7A2-4
Diagnosis .......................................................7A2-5
Manual Transaxle Symptom Diagnosis....... 7A2-5
On-Vehicle Service .......................................7A2-6
Manual Transaxle Oil Change..................... 7A2-6
Differential Side Oil Seal Replacement ....... 7A2-6
Gear Shift Control Lever
and Cable Components .............................. 7A2-8
Gear Shift Control Lever
and Cable Removal and Installation ........... 7A2-9
Gear Shift Control Lever
and Cable Adjustment............................... 7A2-10
Vehicle Speed Sensor (VSS) Removal
and Installation .......................................... 7A2-11
Back Up Lamp Switch Removal
and Installation .......................................... 7A2-12
Back Up Lamp Switch Inspection.............. 7A2-12
Unit Repair Overhaul ..................................7A2-13
Transaxle Unit Components...................... 7A2-13
Transaxle Unit Dismounting
and Remounting........................................ 7A2-14
Transaxle Case Components.................... 7A2-16
Gear Shift and Select Shaft Assembly
Components.............................................. 7A2-18
SECTION 7A2
CONTENTS
Gear Shift and Select Shaft
Assembly Removal and Installation .......... 7A2-18
Gear Shift and Select Shaft Disassembly
and Assembly ........................................... 7A2-20
Fifth Gear Disassembly and Assembly ..... 7A2-20
Gear Shift Shaft, Input Shaft
and Counter Shaft Removal
and Installation.......................................... 7A2-25
Transaxle Right Case Disassembly
and Assembly ........................................... 7A2-31
Transaxle Left Case Disassembly
and Assembly ........................................... 7A2-32
Input & Counter Shaft Components .......... 7A2-34
Input Shaft Disassembly and Assembly.... 7A2-35
Counter Shaft Disassembly
and Assembly ........................................... 7A2-38
Gear Shift Shaft Components ................... 7A2-42
High Speed and Low Speed
Gear Shift Shafts Inspection ..................... 7A2-42
5th & Reverse Gear Shift Shafts
Disassembly and Assembly ...................... 7A2-43
Differential Components ........................... 7A2-43
Differential Disassembly and Assembly.... 7A2-44
Differential Adjustment.............................. 7A2-45
Tightening Torque Specification ............... 7A2-47
Required Service Material.......................... 7A2-48
Special Tool................................................. 7A2-49
MANUAL TRANSAXLE (M15 ENGINE MODEL) 7A2-1
6E1
7A2
7B
8C1
8G3
9
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