Suzuki Wagon R Manual page 3979

7A5-2 MANUAL TRANSAXLE (Z12XEP ENGINE MODEL)
General Description
Manual Transaxle Construction and Servicing
The transaxle provides five forward speeds and one reverse speed by means of three synchronizers and three
shafts-cluster gear (input shaft), main shaft and reverse gear shaft. All forward gears are in constant mesh, and
reverse uses a sliding idler gear arrangement.
The 1st and 2nd speed synchronizer is mounted on main shaft and engaged with main shaft 1st gear or 2nd
gear, also the 3rd and 4th speed synchronizer is done on main shaft and engaged with main shaft third gear or
4th gear.
The 5th speed synchronizer on main shaft is engaged with cluster 5th gear mounted on the cluster gear (input
shaft).
The double cone synchronizing mechanism are provided to 1st and 2nd gear synchromesh device for high per-
formance of shifting to 1st and 2nd gear.
The main shaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which
is made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque
wrench. It is also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reas-
sembling.
New synchronizer rings are prohibited from being lapped with respective gear cones by using lapping com-
pound before they are assembled.