Input Shaft Inspection; Main Shaft Disassembly - Suzuki GRAND VITARA 2005 Service Manual

5B-23 Manual Transmission/Transaxle:
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) Drive in input shaft bearing (1) onto input shaft facing
groove (2) side to downward in figure (3) using
special tool and hydraulic press.
Special tool
(A): 09913–75520
1
3) Select circlip (1) that will make thrust clearance "a" of
bearing 0.15 mm (0.006 in) or less and install it.
Available circlip thickness
1.89 mm (0.074 in.)
1.98 mm (0.078 in.)

Input Shaft Inspection

• Check chamfered teeth of gear for damage and
excessive wear, and replace as necessary.
• Check spline portions and replace parts if excessive
wear is found.
• Check bearing for smooth rotation and replace it if
abnormality is found.
(A)
1
3 2
2
I5JB0B520054-02
2.07 mm (0.081 in.)
I5JB0B520055-01
S5JB0B5206032

Main Shaft Disassembly

1) Remove main shaft bearing circlip using snap ring
pliers.
2) Remove main shaft bearing (1) from main shaft (2)
using bearing puller and hydraulic press.
2
3) Remove circlip (1) using snap ring pliers (2) and then
pull out high speed synchronizer sleeve (5) from high
speed synchronizer hub gradually with holding down
synchronizer key (3) in order to prevent synchronizer
keys and springs (4) from jumping out.
1
4) Remove high speed synchronizer hub (1), 3rd gear
synchronizer ring assembly (2), 3rd gear (3), 3rd
gear needle bearing, 3rd gear bush and 2nd gear (4)
from main shaft (5) using special tool, bearing puller
and hydraulic press.
Special tool
(A): 09925–98220
(A)
3
4
S5JB0B5206022
1
I5JB0B520056-01
5
2
4
3
I5JB0B520057-01
5
1
2
I5JB0B520058-01