Suzuki GRAND VITARA 2005 Service Manual page 458

5B-25 Manual Transmission/Transaxle:
• Put synchronizer outer ring (1), inner ring (2) and
center cone (3) together and then measure step
difference "b" between outer ring and inner ring using
straight edge (4). And also check chamfered tooth of
gear and synchronizer ring. Also, check gear tooth.
Replace with new one if necessary.
Difference "b" between synchronizer outer ring
and center cone (1st)
Standard: 0.4 – 0.8 mm (0.016 – 0.031 in.)
Service limit: 0.2 mm (0.008 in.)
4
• Check clearance "c" between synchronizer outer ring
(1) and center cone (2). If clearance exceeds limit,
replace with new one.
Clearance "c" between synchronizer outer ring
and center cone (1st, 2nd and 3rd)
Standard: 0.41 – 0.7 mm (0.016 – 0.028 in.)
Service limit: 0.3 mm (0.012 in.)
1
4
"b"
3
2
1
1
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"c"
1
2
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• Check clearance "d" between synchronizer center
cone (1) and gear (2) while lightly pushing
synchronizer outer ring by the hand, and also check
chamfered tooth of gear and synchronizer center
cone. Also, check gear tooth. Replace with new one if
necessary.
Clearance "d" between synchronizer center cone
and gear (2nd and 3rd)
Standard: 0.2 – 0.9 mm (0.008 – 0.035 in.)
Service limit: 0.1 mm (0.004 in.)
2
• Check clearance "e" between synchronizer inner ring
(1) and gear (2) while lightly pushing synchronizer
inner ring by the hand, and also check chamfered
tooth of gear and synchronizer inner ring. Also, check
gear tooth. Replace with new one if necessary.
Clearance "e" between synchronizer inner ring
and gear (2nd and 3rd)
Standard: 0.7 – 1.5 mm (0.028 – 0.059 in.)
Service limit: 0.3 mm (0.012 in.)
1
1
"d"
2
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1
"e"
2
2
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