Input Shaft Reassembly - Suzuki GRAND VITARA Owner's Manual

5B-23 Manual Transmission/Transaxle:
• Using cylinder gauge (1), check inside diameter of
each gear. If its inside diameter exceeds specification,
replace it.
Inside diameter (standard) of gear
3rd and 4th gear: 40.000 – 40.025 mm (1.5748 –
1.5757 in.)
• Check chamfered part of each sleeve for damage and
excessive wear, and replace as necessary.
• Check each synchronizer key and synchronizer spring
and replace as necessary.
• Check spline portions and replace parts if excessive
wear is found.

Input Shaft Reassembly

NOTE
• Before installation, wash each part and
apply specified gear oil to sliding faces of
bearing and gear.
• Use new snap rings on shaft for
installation. Don't reuse snap rings.
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) To ensure lubrication, air blow oil holes (1) and make
sure that they are free from any obstruction.
3) Drive in input shaft front bearing (1) to input shaft
using special tool and hammer and then install snap
ring in specified direction as shown in figure.
Special tool
(A): 09940–51710
IYSQ01522099-01
S5JB0A5206018
1
1
I5JB0A520058-01
NOTE
Input shaft front bearing circlip (2) must be
installed before input shaft front bearing is
installed.
2
A: Bearing side
4) Apply oil to high speed gear needle bearing (5), and
then install needle bearing, 4th gear (5) and high
speed synchronizer ring (7) to input shaft.
5) Assemble synchronizer sleeve (4) and hub (3) as
follows.
a) Fit high speed synchronizer sleeve to hub in
specified direction as shown in figure.
b) Insert 3 keys (2) to hub.
c) Set springs (1) at specified position as shown in
figure.
Synchronizer key installation position
: A = B
[A]: 4th gear side
C: Key way
D: Projecting end
(A)
1
A
2
I5JB0A520059-01
I5JB0A520060-01