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Grand Vitara/XL-7 Transmission Factory Service Manual

1. 1 Input gear 13 Washer 25 Circlip 37 Bolt Apply thread lock 99000 31110 to all around thread part of bolt 2 Needle bearing 14 Plate 26 Reduction shift sleeve 38 Needle bearing 3 Input gear bearing 15 Bolt 27 Front drive clutch hub 39 Oil seal Apply thread lock 99000 31110 Apply grease 99000 25010 to all around thread part of bolt to oil seal lip 4 Input bearing circlip 16 Output rear shaft 28 Front drive clutch sleeve 40 Friction ring 5 Input gear circlip 17 Sprocket bush ball 29 Drive sprocket 41 Synchronizer outer ring 6 Oil seal 18 Rear shaft No 1 bearing 30 Needle bearing 42 Center cone Apply grease 99000 25010 to oil seal lip 19 Speedometer drive gear ball 31 Sprocket bush 43 Synchronizer inner ring 8 Counter shaft 20 Rear shaft No 2 bearing 32 Drive chain 44 Synchronizer plate 21 Adjusting shim 33 Output front shaft 45 Synchronizer spring 10 Needle bearing 22 Output low gear 34 Bearing Q Tightening torque 11 O ring 23 Needle bearing 35 Speedometer drive gear 12 Washer ball 24 Reduction clutch hub 36 Circlip 7D 4 TRANSFER 4WD Unit Repair Disassembly 1 Remove 4WD switch 3 and take out steel ball 2 Remove 5 bolts and then remove transfer rear cover 1 if equipped transfer damper bracket 2 and gear shift lever case 4 3 For transfer for A T and TYPE 1 manual transmission after removing bolt of select return syst
2. 1 3007 in MANUAL TRANSMISSION TYPE 2 7A1 23 e Check oil clearance between reverse idle gear 2 and shaft 1 by measuring inside diameter of gear and diameter of shaft and calculate its clearance If clearance exceeds limit replace gear and shaft Oil clearance between reverse idle gear and shaft Standard 0 040 0 082 mm 0 0016 0 0032 in Limit 0 13 mm 0 005 in e Check clearance between reverse idle gear 2 and shoe 1 of reverse gear shift link If clearance exceeds limit replace shoe Clearance between reverse idle gear and shoe Standard 0 05 mm 0 28 mm 0 002 0 011 in Limit 0 5 mm 0 019 in 7A1 24 MANUAL TRANSMISSION TYPE 2 Unit Assembly Gear Shift Lever Case 1 Wash and inspect each part and replace if necessary Also check item as described below and correct whatever neces sary carefully by using reamer oilstone and the like wash it thoroughly and reassemble it Item to be checked is e Shift shaft should go into case smoothly 2 Insert shift shaft 1 as shown in the figure while making sure that inner parts are in proper direction NOTE e Cut off portion 3 in shift shaft 1 should face down ward when shift shaft 1 is installed e Shift lever 2 should be installed at the same time 3 Drive in spring pins 2 for gear shift lever 5 and shift arm 7 NOTE When driving in spring pins position their slits 180 30 apart Special tool A 09
3. 44 Tighten return spring low bolt 2 and return spring reverse bolt Black color 1 NOTE Install return spring reverse bolt Black color 1 to left side of case Tightening torque Return spring reverse bolt Black color a 37 N m 3 7 kg m 27 0 Ib ft Return spring low bolt b 37 N m 3 7 kg m 27 0 Ib ft MANUAL TRANSMISSION TYPE 3 7A2 47 45 Install back up light switch and new gasket Tightening torque Back up light switch a 45 N m 4 5 kg m 32 5 Ib ft 46 Install clutch housing 3 and torque its bolts to specification NOTE Use new to mounting bolts 1 as shown in figure Tightening torque Clutch housing bolt a 36 N m 3 6 kg m 26 0 Ib ft 47 Install clutch release fork 2 and release bearing 1 7A2 48 MANUAL TRANSMISSION TYPE 3 Tightening Torque Specification or Nm kom bt TTansfer ol flerleveland drain plugs o 2 e2 vo Transmission orev and ran pugs s e7 o Back up light switch 4 amp 45 32 5 Gear shift lever case plate screws j 6 06 45 ear case io memede ease bog ar a7 25 Return springlowreverse bois J ay 37 2 Custs ae 80 Tassone af Exhaust No emanis o e es Exhaust No T pipeto erausi No2 ppe bos 180 f s0 s Required Service Material Recommended SUZUKI product ll Lithium grease SUZUKI SUPER GREASE A 99000 25010 e Oil seal lips e Gear shift lever bush e Straight pin Thread lock cement THREAD LOCK 1
4. If measured value is less than standard value remove forward clutch assembly and install it again 2 Forward clutch 16 Apply grease to thrust forward clutch bearing and install it to forward clutch input shaft Also apply grease to thrust rear race and install it to O D case 1 Planetary ring gear side 2 Forward clutch side 17 Install O D case by aligning cutout in O D case 1 and that in transmission case NOTE Use care not to drop thrust rear race installed to O D case 2 Cutout in automatic transmission 18 Apply grease to thrust planetary rear washer and install it to O D planetary gear Also apply grease to thrust planetary ring front race and install it to planetary ring gear and then install O D input shaft assembly to O D case NOTE e Fit claws of thrust planetary rear washer and thrust planetary ring front race into holes securely e Use care not to drop thrust planetary rear washer installed to O D planetary gear AUTOMATIC TRANSMISSION 4 A T 7B1 57 19 When clutch disc or plate has been replaced check height difference between O D case and O D clutch cylinder by measuring it as shown in the figure Standard height difference a between O D case and O D clutch cylinder About 3 5 mm 0 138 in NOTE Measure at the highest point along inner circumference of O D clutch cylinder 20 Apply A T fluid to new housing O ring and install it to O D case Then install converter housi
5. Special tool A 09912 34510 8 Remove input shaft bearing retainer 1 and gasket 7A1 10 MANUAL TRANSMISSION TYPE 2 9 Remove C ring 1 of input shaft bearing and C ring 2 of counter shaft front bearing Special tool B 09900 06107 10 Using special tool separate transmission front case 1 and transmission intermediate case 2 Special tool A 09912 34510 11 Set transmission on workbench and remove transmission front case 1 NOTE To remove transmission front case tilt it as shown in the figure 12 Set transmission intermediate case on vise securely 13 Remove locating screws 1 locating springs 2 and locat ing ball 3 as shown in the figure 14 Using special tool remove spring pin and then remove 5th reverse gear shift shaft 1 Special tool C 09922 85811 MANUAL TRANSMISSION TYPE 2 7A1 11 15 Remove bolt from 5th gear shift fork 1 16 Remove 5th gear shift fork 1 5th gear shift shaft 3 and reverse gear shift yoke 2 NOTE When pulling 5th gear shift shaft 3 place hand so as to catch balls 4 dropping from reverse gear shift yoke 2 and intermediate plate 17 Remove locating roller No 2 1 from reverse gear shift shaft 2 by using magnet 3 18 Remove circlip 1 from reverse gear shift shaft 2 as shown in the figure 19 Remove spring pin from reverse gear shift link component Special tool C 09922 85811 7A1 12 MANUAL TR
6. 2 Remove bearing race and thrust bearing 1 Thrust bearing No 2 2 Thrust forward clutch bearing 3 Thrust rear race 3 Install direct clutch input hub 1 and retaining ring 2 4 Install forward clutch 2 to O D case 1 Apply 4 8 kg cm air pressure into fluid hole at the right of cut in O D case and measure movement of forward clutch piston If measured value is not within standard range use either 1 8 mm 0 071 in or 2 0 mm 0 079 in clutch disc to adjust it to standard value Standard forward clutch piston movement 1 40 2 24 mm 0 056 0 088 in 7B1 22 AUTOMATIC TRANSMISSION 4 A T 5 Remove retaining ring 1 and then remove direct clutch input hub 6 Remove retaining ring and then remove all clutch discs 7 Using special tool and hydraulic press compress forward clutch piston return spring and remove retaining return spring Special tool A 09926 98310 CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform 8 Remove forward clutch piston return spring 9 Install forward clutch to O D case Blow low pressure air into fluid hole at the right of cut in O D case to remove forward clutch piston INSPECTION Forward Clutch Piston e Shake piston to check that ball is not stuck e Blow low pressure air to check ball section for leakage AUTOMATIC TRANSMISSION 4 A T 7B1 23 Forward Clutch Piston Retur
7. 2 00 2 05 mm 0 0788 0 0807 in Special tool B 09900 06107 MANUAL TRANSMISSION TYPE 3 7A2 29 5 After installing circlip check that 3rd gear turns lightly 6 Check 3rd gear 2 thrust clearance using thickness gauge 1 If clearance is out of specification repress fit or replace 3rd gear thrust clearance Standard 0 10 0 25 mm 0 004 0 009 in 7 Assemble low speed synchronizer hub 3 sleeve 4 springs 1 and keys 2 according to the following proce dure a Install Synchronizer springs 1 and synchronizer keys 2 to low speed synchronizer hub 3 as shown in figure b Slide low speed synchronizer hub 3 in sleeve 4 so that flange side of sleeve 4 and small diameter boss side of hub 3 face opposite as shown the figure also aligning hub slots with key location teeth of sleeve 4 A Key location teeth B Flange side C Small diameter boss a lt b D 2nd gear side 8 Assemble 2nd gear 1 synchronizer inner ring 2 synchro nizer cone ring 5 and synchronizer outer ring according to the following procedure a Install synchronizer inner ring 2 to 2nd gear 1 b Install synchronizer cone ring 5 to 2nd gear 1 NOTE Fit protrusion 4 of synchronizer cone ring 5 into groove 3 of 2nd gear c Install synchronizer outer ring 1 to 2nd gear 2 7A2 30 MANUAL TRANSMISSION TYPE 3 d Install 2nd gear 3 fitting slot of low speed
8. Circlip thickness specification mark Circlip thickness Aa 280 2 85 mm 0 1103 0 1122 in 8 285 290mm 0 1122 0 1141 in pp ee Fr ee 2 Thickness gauge 15 Fix with circlip 1 as shown in the figure and check that counter 5th gear turns lightly 16 Check counter 5th gear 1 thrust clearance by using thick ness gauge 2 Counter 5th gear thrust clearance Standard 0 1 0 3 mm 0 0040 0 0118 in 17 Install low speed gear shift fork high speed gear shift fork and shaft 18 Apply thread lock cement to thread of fork bolt and tighten bolt to specification A Cement 99000 32020 Tightening torque Shift fork bolt a 20 N m 2 0 kg m 14 5 Ib ft 7A1 38 MANUAL TRANSMISSION TYPE 2 19 Fix new circlip 1 to high gear shift shaft by using lever or the like and hammer 20 Apply grease A to locating roller No 2 1 and install roller 1 to low gear shift shaft 2 A Grease 99000 25010 21 Supporting locating roller No 3 1 by magnet 2 insert low gear shift shaft 3 to intermediate case and low speed gear shift fork 22 Apply thread lock cement A to thread of fork bolt and tighten bolt to specification A Cement 99000 32020 Tightening torque Shift fork bolt a 20 N m 2 0 kg m 14 5 Ib ft 23 Fix with new circlip 1 to low gear shift shaft 2 by using lever or the like and hammer MANUAL TRANSMISSION TYPE
9. 99000 25030 e Oil seal lips e Oil pump O ring ee ae GREASE A Cable ends 00002 Sealant SUZUKI BOND No 1215 e Mating surface of transmission case ee ee AUTOMATIC TRANSMISSION 4 A T 7B1 67 Special Tool 09920 76010 09941 84510 09918 48211 09918 48220 Snap ring opener Bearing inner race Oil pump remover Oil pump remover remover attachment M8 lA 09926 98320 09926 98310 09900 20606 09900 20701 Spring compressor Clutch spring compressor Dial gauge Magnetic stand No 1set 09943 88211 Bearing installer 7B1 68 AUTOMATIC TRANSMISSION 4 A T TRANSFER 4WD 7D 1 SECTION 7D TRANSFER 4WD CONTENTS General Description cccscceeseeeeeeeeeeeeeseeesees 7D 2 ASSEN cece hose tice N 7D 11 COMPONEN S ori 7D 2 Tightening Torque Specification 7D 23 UME RED AIF ukene 7D 4 Required Service Material 0000 7D 23 Disassembly ccccccecceceecceeeeeeeceeeeeeeeeeeseeeeess 7D 4 Special Tooluusasrasssrase 7D 24 Component Inspection rrrrnrnnnnnnnnnnnnnnnn 7D 10 7D 2 TRANSFER 4WD General Description Components 6 6 4 5 18 at fa HULE 0 35 ae mm HER HEN I 1 TES HST im ce Fem NOT mer tll lie e Cry Font f F dt 2 Og eS CW 5 Drive sprocket 20 Transfer center case oil seal TRANSFER 4WD 7D 3 Ve 44 37 pi 3338 8 10 N m 1 0 kg m 15 UV 23 N m 2 3 kg m D
10. d Remove bevel pinion with rear bearing shim and spacer from carrier If it is hard to remove screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on pinion e Remove bevel pinion rear bearing 2 by using bearing puller 3 and press 1 Drive bevel pinion 7 Using a hammer and brass bar 1 drive out front bearing outer race with bearing 2 and oil seal 3 8 Drive out rear bearing outer race in the same way as in the step 7 7F 6 DIFFERENTIAL REAR Component Inspection e Check companion flange for wear or damage e Check bearings for wear or discoloration e Check differential carrier for cracks e Check drive bevel pinion and bevel gear for wear or cracks e Check side gears pinion gears and pinion shaft for wear or damage e Check side gear spline for wear or damage Sub Assembly Adjustment and Reassembly Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc after disassembly prepare replacing parts and proceed to reas sembly according to procedures as described below CAUTION e Bevel gear and pinion must be replaced as a set when either replacement becomes necessary e When replacing taper roller bearing replace as inner race amp outer race assembly Differential carrier For press fitting bevel pinion bearing outer races use special tools as shown in the figure Spe
11. 2 Pull out center support assembly 2 from planetary sun gear 1 3 Apply 4 8 kg cm air pressure into fluid hole at the extreme left and measure movement of B1 brake Second coast brake piston If measured value is not within standard range replace B1 brake plate or B1 brake disc Standard B1 brake piston movement 1 00 1 20 mm 0 039 0 047 in 4 Remove retaining ring 7B1 30 AUTOMATIC TRANSMISSION 4 A T N ja ie 5 After removing clutch backing plate 1 remove B1 brake plates 3 and B1 brake discs 2 6 Using special tool and hydraulic press compress piston return spring and remove snap ring CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform Special tool A 09926 98310 7 Remove brake piston return spring 1 8 Blow air into fluid hole at the extreme left and remove B1 brake piston as shown in the figure Then remove piston inner O ring and piston outer O ring from B1 brake piston 9 Remove 3 seal rear rings 1 NOTE Use care not to open ring more than necessary AUTOMATIC TRANSMISSION 4 A T 7B1 31 10 Apply 4 8 kg cm air pressure into the second hole from the left and measure stroke of B2 brake Second brake pis ton as shown in figure If measured value is not within standard range replace B2 brake plate or B2 brake disc Standard B2 brake piston stroke 1 01 2 25 mm
12. 2 installed to oil pump 1 apply 4 to 8 kg cm air pressure into fluid hole in oil pump and measure stroke of clutch piston If it is not within standard range replace cushion clutch plate or clutch disc Standard stroke of clutch piston Standard 1 47 2 28 mm 0 058 0 089 in 4 Remove retaining ring 1 and then remove brake hub 2 5 Remove retaining clutch ring 1 cushion plate backing plate and clutch disc in that order 6 With clutch piston return spring compressed with special tools remove clutch piston return spring Special tool A 09918 48211 B 09926 98320 C 09918 48220 1 Snap ring AUTOMATIC TRANSMISSION 4 A T 7B1 15 7 Install O D clutch cylinder to oil pump 2 Apply compression air into fluid hole in oil pump 2 and remove clutch piston 1 8 Remove piston inner O ring and piston outer O ring from clutch piston 1 9 Remove retaining ring from O D planetary gear and then remove one way clutch thrust planetary washer and thrust bearing INSPECTION e Check that ball valve of clutch piston is not stuck e Check valve for leakage by applying low pressure air into ball valve hale ASSEMBLY Assemble each component by reversing removal procedure and noting the following points e When installing thrust washer 1 bring its oil groove 3 to the front VJ EEE e ES He e When installing one way clutch to one way clutch outer race HR BLA bring
13. 4 between vise 3 and bearing retainer 2 to protect bearing retainer 2 against dam age 2 Remove oil seal 1 from bearing retainer 2 using special tool if necessary NOTE Unless oil seal is leaky or its lip is excessively hardened replacement is not necessary Special tool A 09913 50121 MANUAL TRANSMISSION TYPE 3 7A2 19 Transmission rear case 1 Remove counter shaft gutter 2 from transmission rear case 1 2 Take out oil seal 1 from rear case 2 3 Remove interlock cam plug 1 by using torx 2 4 Remove interlock cam pin using special tool Special tool A 09922 85811 7A2 20 MANUAL TRANSMISSION TYPE 3 5 Pull out interlock cam component 1 Components Inspection Sub Assembly Input Shaft Assembly Check clearance a between synchronizer ring and gear width of index protrusion b in synchronizer ring key slot width c in high speed synchronizer hub and each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring and gear input shaft Standard 0 7 1 7 mm 0 028 0 067 in Service limit 0 5 mm 0 020 in Width of index protrusion b input shaft Standard 3 9 4 1 mm 0 154 0 161 in Service limit 3 6 mm 0 142 in Key slot width c high speed synchronizer hub Standard 8 0 8 1 mm 0 315 0 319 in M
14. B D d Select a shim from among following available sizes and install it in bearing bore of rear case CAUTION Installing of over sized shim beyond specification in the following table may cause tight rotation of rear shaft and consequential bearing damage Shim specification 0 0i3mm 0 0005in NONEED 0 43 0 53 mm 0 017 0 021 in 0 4 mm 0 016 in 0 53 0 58 mm 0 021 0 023 in 0 5 mm 0 020 in 0 33 0 43 mm 0 013 0 017 in 0 3 mm 0 012 in 38 Clean mating surfaces of both center 2 and rear 1 cases again apply sealant to mating surface of rear case C Sealant 99000 31110 3 Install shim 39 Put together center case 1 and rear case 2 with installing yoke 3 to reduction shift shaft 4 TRANSFER 4WD 7D 21 40 Torque 15 rear case bolts 2 to specification NOTE After tightening bolts provisionally install universal joint flange into rear shaft and check to make sure smooth rotation of shaft Tightening torque Rear case bolt e 23 N m 2 3 kg m 17 0 Ib ft 1 Clamp 41 For transfer for TYPE 2 and TYPE 3 manual transmission perform the following procedure a With reduction shift shaft shifted to high speed side fit yoke to shaft and install return spring 2 as shown in the figure Tighten bolt 1 to specified torque Tightening torque Select return spring bolt TYPE 2 and TYPE 3 M T f 5 5 N m 0 55 kg m 4 0 Ib
15. Fit straight end of shift limit spring 2 into line groove in shift limit yoke 3 and with its other hooked end turned in its winding direction by about 90 from its free state hook it on spring pin 1 7 Drive in spring pin for shift arm 8 Press fit case plug 1 into case 2 and caulk it with punch A Caulking 9 If reverse gear shift limit bolt 1 has been removed apply thread lock cement A to bolt then install and torque it to specification A Cement 99000 32020 Tightening torque Reverse gear shift limit bolt a 23 N m 2 3 kg m 17 0 Ib ft 2 Gear shift lever case 10 Install gear shift lever case 3 to transmission without using sealant for functional check 11 Install shift control lever 1 and check to make sure that it shifts smoothly according to shift pattern as shown in the fig ure NOTE e Apply thread lock cement A to control lever locating bolts 2 when replaced e Be sure to apply sealant to mating surface of gear shift lever case 3 for its final installation A Cement 99000 32020 Tightening torque Control lever locating bolt a 17 N m 1 7 kg m 12 5 Ib ft 7A 22 MANUAL TRANSMISSION TYPE 1 Sub Assembly Main shaft 3 14 15 16 LE Feliks NO D rer ft sO EE aeee FEN T NON war O Input shaft bearing 7 Synchronizer low speed ring 13 Synchronizer reverse sleeve and hub assembly 2 Inputshaft 2 Inputshaft 8 Synchro
16. Special tool C 09922 85811 MANUAL TRANSMISSION TYPE 2 7A1 41 35 Install locating balls locating springs and locating screw after checking free length of locating springs Free length of locating springs 31 0 mm 30 1 mm Tom 20 2 mm 19 6 mm 7 mm Omm NOTE For 5th gear locating spring use shorter spring 1 A Cement 99000 32020 Tightening torque Locating spring screw a 19 N m 1 9 kg m 14 0 Ib ft 36 Place intermediate case assembly upright as shown in the figure by using workbench or the like 37 Apply sealant evenly to front case side of intermediate case 1 as shown A Sealant 99000 31110 38 Clean mating surface of front case 1 and install it to inter mediate case 7A1 42 MANUAL TRANSMISSION TYPE 2 39 Fix C rings 1 2 to bearings as shown in the figure Special tool A 09900 06107 40 Apply cement A to input shaft bearing retainer bolt and install input shaft bearing retainer 1 new gasket and its bolts A Cement 99000 32020 Tightening torque Input shaft bearing retainer bolt a 17 N m 1 7 kg m 12 5 Ib ft 41 Clean mating surface of rear case and apply sealant evenly to rear case side of intermediate case Sealant 99000 31110 42 Install rear case to intermediate case Tightening torque Rear case to intermediate case bolt a 35 N m 3 5 kg m 25 5 Ib ft 1 Bolt Longest 2 Bolt Middle MANUAL TRANSMISSI
17. and 5th amp reverse synchronizer ring 7 according to the following procedure a Fit plate spring 1 to counter shaft 5th gear 3 and fix spring with circlip 2 using special tool Special tool A 09900 06107 MANUAL TRANSMISSION TYPE 3 7A2 39 b Install 5th amp reverse synchronizer sleeve 1 to counter shaft 5th gear 2 in specified direction as shown in figure A Chamfered side c Fit balk levers 1 to counter shaft 5th gear in specified direction as shown in figure d Install synchronizer key spring 1 e Push balk lever and synchronizer key spring and slide 5th amp reverse synchronizer sleeve 1 until sliding surface of balk lever is locked into key location teeth of 5th amp reverse synchronizer sleeve 1 f Install synchronizer ring 1 to counter shaft 5th gear 4 NOTE Aligne protrusion 2 of synchronizer ring 1 and groove 3 of counter shaft 5th gear 4 7A2 40 MANUAL TRANSMISSION TYPE 3 11 Install needle bearing 1 into counter shaft 5th gear assem bly 2 which was assembled in Steps a to f 12 Install counter shaft 5th gear assembly 2 to counter shaft 3 facing gear side to plate 13 Press fit 5th speed synchronizer dog 1 to counter shaft with press 2 and special tool Special tool A B 09913 84510 ner tad Ws oe A 14 Select circlip 1 that will make clearance in circlip groove 0 1 mm 0 0039 in or less Circlip thickness specif
18. center case 1 As shown in the figure apply straightedge 2 to top surface of case and press fit till limit line 8 of spe cial tool aligns with bottom surface of straightedge 2 i e case surface NOTE e Press fitting needle bearing according to above proce dure will set needle bearing 3 mm before it hits case bottom e Once it is press fit all way down to case bottom removal would be very difficult if it becomes neces sary Special tool A 09951 76010 7D 12 TRANSFER 4WD 2 Using special tool and hammer drive oil seal 1 into center case 2 until it becomes flush with case surface Apply grease A to oil seal lip A Grease 99000 25010 Special tool B 09913 75520 3 Install oil gutter 3 to center case 2 and tighten bolt 1 applying thread lock cement B Tightening torque Center case gutter bolt a 8 N m 0 8 kg m 5 5 Ib ft B Cement 99000 32020 4 Using special tool and press install needle bearing into rear case 1 As shown in the figure apply straightedge 2 to case surface and press fit till top of special tool 3 aligns with bottom surface of straightedge i e case surface NOTE As with needle bearing in center case above installation procedure will set needle bearing at a position 3 mm before it hits case bottom Special tool A 09951 76010 5 Using special tool and hammer install oil seal 1 into rear case 2 until it becomes flus
19. 0 010 0 033 in Limit 1 0 mm 0 039 in e Check clearance between synchronizer ring and synchro nizer dog and each chamfered tooth of synchronizer dog and synchronizer ring and replace with new one if necessary Also check gear tooth Clearance between synchronizer ring and synchronizer dog counter shaft Standard 0 68 1 32 mm 0 027 0 052 in Service limit 0 5 m 0 020 in e Using cylinder gauge 1 check inside diameter of counter shaft 5th gear 2 If measured value exceeds specification replace gear Counter shaft 5th gear diameter Standard 38 015 38 040 mm 1 4967 1 4976 in e Check oil clearance between reverse idle gear 2 and shaft 1 measuring inside diameter a of gear and diameter b of shaft and calculate as follows Clearance o Ha JE b If clearance exceeds limit replace gear and shaft Oil clearance c between reverse idle gear and shaft Standard 0 040 0 082 mm 0 0016 0 0032 in Limit 0 13 mm 0 005 in e Check clearance between reverse idle gear 2 and shoe 1 of reverse gear shift arm If clearance exceeds limit replace shoe Clearance between reverse idle gear and shoe Standard 0 05 mm 0 35 mm 0 002 0 014 in Limit 0 5 mm 0 019 in MANUAL TRANSMISSION TYPE 3 7A2 25 Unit Assembly Gear Shift Lever Case 1 Wash and inspect each part and replace if necessary Also check item as described
20. 0 040 0 088 in 11 After removing retaining back plate ring remove clutch back ing plate B2 brake plates and B2 brake discs 12 Using special tool and hydraulic press compress brake pis ton return spring and remove snap B1 brake ring CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform Special tool A 09926 98310 13 Remove brake piston return spring 14 Blow air into the second air hole from the left and remove B2 brake piston Then remove piston inner O ring and piston outer O ring from B2 brake piston 7B1 32 AUTOMATIC TRANSMISSION 4 A T 15 With B2 brake hub assembly 3 held stationary turn plane tary sun gear 4 clockwise to check that it locks and then counterclockwise to check that it turns smoothly A Locks B Turns 16 Remove B2 brake hub assembly 1 from planetary sun gear 2 17 Remove 2 sun gear seal rings 1 from planetary sun gear NOTE Use care not to open sun gear seal ring more than neces sary ASSEMBLY Assemble components by reversing disassembly procedure and noting the following points e Snap both ends of sun gear seal ring 1 securely Do not open sun gear seal ring more than necessary e Always use new O ring and apply A T fluid before installa tion e When installing O ring make sure that it is not kinked or caught e Push in brake piston horizontally e When instal
21. 09951 46010 4 differential pinion type 2 Tighten flange nut 1 so that specified bearing preload is obtained NOTE Before taking measurement with spring balance 2 or torque wrench 3 check for rotation by hand and apply small amount of oil to bearings Special tool B 09926 78311 C 09922 75222 Pinion bearing preload 9 0 17 0 kg cm 7 8 14 7 Ib in Spring measure reading with special tool 1 8 3 4 kg 4 0 7 5 Ib 4 Socket with adapter 3 Set dial gauge to bevel pinion mounting dummy and make 0 Zero adjustment on surface plate NOTE e When setting dial gauge to mounting dummy tighten screw lightly Be careful not to overtighten it which will cause damage to dial gauge e With dial gauge set turn dummy back and force by hand a couple of times and attain accurate 0 zero adjustment e It is desirable that short pointer indicates beyond 2 mm when long one is at 0 zero Special tool A 09900 20606 B 09926 78311 1 Surface plate 7F 12 DIFFERENTIAL REAR 4 Place zero adjusted mounting dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip NOTE e Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accu rately e When dial gauge measuring tip extends from 0 Zero position pointer turns counterclockwise e Measured value may exceed 1 mm Therefo
22. 13 N m 1 3 kg m 9 5 Ib ft 10 As final step check gear tooth contact as the follows a After cleaning tooth surface of 10 bevel gears paint them with gear marking compound evenly by using brush or sponge etc b Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact c Bring painted part up and check contact pattern referring to the following table If contact pattern is not normal readjust or replace as necessary according to instruction in chart NOTE Be careful not to turn bevel gear more than one full revo lution for it will hinder accurate check A Paint gear marking compound evenly DIFFERENTIAL FRONT 7E 17 TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY NORMAL Outer end Heel Drive side Coast side Inner end Toe HIGH CONTACT Pinion is positioned too far from the center of driver Gear bevel gear 1 Increase thickness of pinion height adjusting shim and position pinion closer to gear center Pinion 2 Adjust drive bevel gear backlash to specifica tion LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height adjusting shim and position pinion farther from gear cen ter 2 Adjust drive bevel gear backlash to specifica tion If adjustment is impossible replace differential carrier 1 Check seating of bevel gear or differential case Check bevel
23. 2 or 3 turns and press down bearing cap by hand NOTE If bearing cap does not fit tightly on carrier side bearing adjuster is not threaded properly Reinstall adjuster 5 Tighten cap bolts to provisional torque below Tightening torque Side bearing cap bolt provisional torque a 15 N m 1 5 kg m 11 0 Ib ft 6 Install actuator bracket to bearing cap and tighten its bolts to specification Tightening torque Actuator bracket bolt b 12 N m 1 2 kg m 8 5 Ib ft 7 Tighten both bearing adjusters 1 so as to obtain specified gear backlash and at the same time obtain preload of side bearing Special tool A 09930 40120 Attachment B 09930 40113 Rotor holder C 09900 20701 Bevel gear backlash 0 13 0 18 mm 0 005 0 007 in NOTE e Be sure to apply measuring tip of dial gauge 1 at right angles to convex side of tooth e Measure at least 4 points on drive bevel gear periph ery e As a practical measure the following would be recom mended to obtain specified backlash and side bearing preload at the same time a Obtain specified backlash by turning both adjusters inward lightly b Tighten both adjusters further by one notch at a time DIFFERENTIAL FRONT 7E 15 8 Measure preload of pinion with spring balance 1 or torque wrench 2 and check composite preload of pinion bearing and side bearing Special tool D 09922 75222 NOTE Standard preload is shown in the gr
24. 3 to transmission case 27 Apply grease to lip of new oil lip seal and drive in oil lip seal with special tool till it contacts transmission case Special tool A 09943 88211 28 After installing new sleeve cover to manual shift lever 1 install manual shift shaft 2 and manual shift lever 1 to transmission case AUTOMATIC TRANSMISSION 4 A T 7B1 59 29 Align hole in manual shift shaft with that in manual shift lever and drive in new manual shift lever pin 1 30 Align hole in sleeve cover with dent in manual shift lever and caulk securely with pin punch 1 Then check that manual shift shaft turns smoothly 31 With parking lock rod 1 installed to manual shift lever place parking lock rod 1 on parking lock pawl 2 as shown in the figure Then install pawl bracket and tighten bracket screw to specified torque Tightening torque Pawl bracket screw 7 5 N m 0 75 kg m 5 5 Ib ft 32 Apply A T fluid to new throttle cable O ring 2 and install it to throttle cable then connect throttle cable 1 to transmission case 3 NOTE Do not turn transmission case toward position where throttle cable is connected so as to protect retainer of throttle cable 7B1 60 AUTOMATIC TRANSMISSION 4 A T 33 Apply A T fluid to new O ring and spring and install them to accumulator piston and install accumulator piston to trans mission case 4 Upper spring 5 Coil outer diameter Accumulator piston and
25. 3 kg m 17 0 Ib ft 6 Washer aluminum 7 Counter shaft reverse gear 8 Counter shaft 5th gear MANUAL TRANSMISSION TYPE 1 7A 27 7 After press fitting rear bearing 1 to counter shaft make sure to fit circlip securely Special tool E 09913 80113 8 Fit circlip 1 around front bearing 2 and check to make sure that circlip just contacts with case surface Upper case and shifter Interlock system is as shown in the figure 1 Locating ball 2 Rubber plug 3 Reverse gear shift shaft 4 Interlock ball 5 Interlock pin 6 High speed gear shift shaft 7 Low speed gear shift shaft 4 Wl me w ma ek ene LUN N TT DE SUTTA 1 With fork installed to reverse gear shift shaft 1 install it into case and put in interlock ball 2 7A 28 MANUAL TRANSMISSION TYPE 1 NOTE Reverse gear shift fork spring pin is different from other spring pins in length It is longer than other spring pins 1 Reverse gear shift fork spring pin 2 Low amp High gear shift fork spring pin 3 High speed gear shift fork 4 Low speed gear shift fork 5 Reverse gear shift fork NOTE 3 5 4 5 mm When pressing gear shift fork spring pin 1 into reverse pie eee gear shift fork 2 do not allow to go all the way in but leave its end protruded as much as the length shown in the figure 2 With interlock pin fit to high speed gear shift shaft 2 insert it into case and set fork with spring pin and
26. 31110 Mating surface of front case Mating surface of rear case Mating surface of gear shift lever case 7D 24 TRANSFER 4WD 09900 06107 Snap ring plier Opening type 09913 80112 Bearing installer 09922 85811 Spring pin remover 09940 53111 Bearing installer 09900 06108 Snap ring plier Closing type 09913 84510 Bearing installer 09925 18011 Bearing installer 09941 64511 Bearing remover Special Tool 09912 34510 Separator 09921 57810 Bearing remover 09925 98221 Bearing installer 09951 16080 Bearing installer 09913 75520 Bearing installer 09927 18411 Universal puller 09926 68310 Bearing installer 09951 26010 Bush remover plate TRANSFER 4WD 7D 25 Dy Pi S 09951 76010 Bearing installer 7D 26 TRANSFER 4WD DIFFERENTIAL FRONT 7E 1 SECTION 7E DIFFERENTIAL FRONT CONTENTS General Description c cccceeceeeeeeeeeeeeeeeeees 7E 2 Differential Carrie siioni nii 7E 8 COMPONE gassenes 7E 2 Differential Case sirain 7E 8 Unit Repair EE 7E 3 Drive bevel pinion ssssssssrrrrrsssssssssnnnnns 7E 10 Disassembly Unit resrvrvvrvvrvvrvverververververvenner 7E 3 hes Den Fe eerene mer ce Components Inspection serrvervevrvrvrrvernnne 7E 6 Tightening Torque Specification 7E 18 Differential left case c s srrvrvrnnrrvrvnnennn 7E 6 Required Service Material ssesseeee 7E 19 FEE END deren mmene nee oan eee mene er
27. Tighten rear upper valve body plate 1 bolt to specified torque Tightening torque Rear upper valve body plate bolt 5 5 N m 0 55 kg m 4 0 Ib ft 7B1 48 AUTOMATIC TRANSMISSION 4 A T Lower valve body 12 13 1 Lower valve body 5 Lower valve body plate 9 TCC Lock up control sleeve 13 Primary regulator valve sleeve 2 Spring 6 Lower valve body gasket 10 TCC Lock up control valve 14 Primary regulator valve plunger 3 Pressure relief valve ball 7 TCC Lock up control valve plate 15 Primary regulator valve 4 Pressure relief valve retainer 8 TCC Lock up control valve gasket 12 Retainer 16 Spacer AUTOMATIC TRANSMISSION 4 A T 7B1 49 DISASSEMBLY 1 Remove bypass valve 1 bypass valve spring check ball valve damping spring valve body ball 2 and ball valve spring 3 Check ball 4 Primary regulator valve sleeve retainer 5 Locating pin 2 Remove lower valve body plate 1 and lower valve body plate gasket 3 Remove TCC lock up control valve plate 2 and TCC lock up control valve gasket 4 With pressure relief valve retainer 1 pressed with finger remove pressure relief valve bolt and then remove pressure relief valve retainer 1 pressure relief valve spring and pres sure relief valve ball 5 Remove TCC lock up solenoid valve 1 and then remove O ring 2 from TCC solenoid valve 1 7B1 50 AUTOMATIC TRANSMISSION 4 A T 6 After removing shift solenoid valve A
28. a ved F AN 3 Remove 3rd synchronizer ring 2 3rd gear 1 and needle bearing T NOTE High speed sleeve hub assembly synchronizer ring 2 and 3rd gear 1 can be removed all at once by using puller and hydraulic press 4 Remove circlip in the rear part of main shaft 1 and pull off rear bearing 2 with bearing puller 3 and press 5 Remove thrust washer and steel ball and then remove 5th gear synchronizer ring and needle bearing 6 Pull out reverse sleeve from its hub 2 and remove 3 syn chronizer keys 7 Remove circlip and pull off reverse hub 2 from main shaft 1 with bearing puller 3 and press then take out synchro nizer springs NOTE It is also possible to remove reverse sleeve hub as assembly and reverse gear all at once by using puller and press after removing circlip 8 Remove main shaft reverse gear and needle bearing by hand MANUAL TRANSMISSION TYPE 1 7A 13 9 Using bearing puller 4 and press remove reverse gear bush 2 and bearing washer 3 from main shaft 1 NOTE During above work watch out for steel ball which will come out from inside of washer so as not to lose it CAUTION Do not attempt to pull out bearing washer 3 and bush 2 all together at once Steel ball would stop bearing and cause damage to it 10 Pull off bearing 1 with bearing puller 2 and press 11 Remove the following in that order bearing washer steel ball low gear l
29. amp B 1 remove sole noid valve gasket low coast modulator valve spring 2 inter coast modulator valve spring 3 and 2 intermediate coast modulator valves 4 7 Pressing TCC lock up control sleeve with finger and using magnet 1 remove locating pin and then remove TCC lock up control sleeve TCC lock up control valve and TCC lock up control valve spring 8 Check which step of primary regulator valve sleeve 1 how many steps down from its tip contacts primary regulator valve sleeve retainer 2 9 Pressing primary regulator valve sleeve 1 with finger and using magnet remove primary regulator valve sleeve retainer and then remove primary regulator valve sleeve 1 spacer 2 primary regulator valve plunger 3 primary regu lator valve spring 4 and primary regulator valve 5 AUTOMATIC TRANSMISSION 4 A T 7B1 51 ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points e Coil outer diameter and free length of each valve spring should be as listed below Be sure to use each one of correct Size Coil outer diameter and free length of each valve spring Low coast modulator valve spring Inter coast modulator valve spring 9 04 mm 0 356 in 27 26 mm 1 073 in 10 00 mm 0 394 in 25 60 mm 1 008 in Bypass valve spring 13 82 mm 0 544 in 28 90 mm 1 138 in Primary regulator valve spring 17 02 mm 0 670 in 50 28 mm 1 980 in e Install pri
30. b Remove differential left case 2 from differential right case c Drive out spring pin with special tool and hammer and dis assemble differential side gears pinions washers and shaft in differential case 1 Special tool A 09922 85811 4 For 4 differential pinion typel remove drive bevel gear pinion gear and pinion shaft a Remove bevel gear by removing its bolts in the same man ner as step a of 2 differential pinion type Step 3 b There are 8 bolts fastening two differential case halves together Remove these bolts to sever right hand case half from left hand one and take off right hand one Special tool B 09930 40113 7F 4 DIFFERENTIAL REAR c Remove pinion shaft side gears washers differential pin ions spring washers thrust washers 5 Using special tools pull out differential side bearings 1 Special tool C 09913 85230 D 09913 61510 6 Remove bevel pinion assembly a Hold universal joint flange with special tool and then remove flange nut by using power wrench 4 10 magnifi cation 2 Special tool E 09922 66020 1 Socket wrench b Make mating marks 1 on drive bevel pinion and compan ion flange CAUTION Don t make mating mark on the coupling surface of the flange c Remove companion flange from pinion Use special tool if it is hard to remove Special tool F 09913 65135 SN IPS a i A J DIFFERENTIAL REAR 7F 5
31. bearing cap bolts 2 or 3 turns and press down bearing cap by hand NOTE If bearing cap does not fit tightly on carrier side bearing adjuster is not threaded properly Reinstall adjuster 5 Tighten cap bolts provisional torque Tightening torque Bearing Cap bolt Provisional torque a 15 N m 1 5 kg m 11 0 Ib ft 6 Tighten both bearing adjusters 2 so as to obtain specified gear backlash and at the same time obtain preload of side bearing NOTE e Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth e As a practical measure the following would be recom mended to obtain specified backlash and side bearing preload at the same time Obtain specified backlash by turning both adjusters inward lightly Tighten both adjusters further by one notch at a time e Measure at least 4 points on drive bevel gear periph ery l MgA Aull Standard backlash 0 13 0 18 mm 0 005 0 007 in Special tool A 09930 40120 B 09930 40113 C 09900 20701 1 Bearing cap bolt DIFFERENTIAL REAR 7F 15 7 Measure preload of pinion with spring balance 1 or torque wrench 2 and check composite preload of pinion bearing and side bearing NOTE e Standard preload is shown in the following graph which should be read as follows Example When preload of bevel pinion is 26 N 2 6 kg 5 73 Ib acceptable composite preload of both pinion bearings and s
32. for steel ball which comes off from shaft when bush is pulled out so as not to lose it 7D 6 TRANSFER 4WD 10 Remove counter shaft plate bolt 1 from front case 3 and counter shaft plate will come off 11 Remove front case 3 by removing its 9 bolts 2 12 Remove input gear needle bearing 1 13 Remove counter gear 2 shaft 3 together with counter gear 2 needle bearings function ring washers 4 and steel balls 5 from case NOTE e Watch out for steel balls which come out from between shaft and washers front and rear so as not to lose them Check friction ring lip for damage and wear Replace if necessary Neither O ring nor friction ring should be removed unless absolutely necessary If removed use new parts for reinstallation Removed ones should not be reused 14 Remove O ring from counter gear shaft 2 and then remove friction ring 3 from shaft using a proper size rod 1 and press 15 Remove locating spring bolt 1 with washer 2 if equipped spring 3 and ball 4 for reduction shift 16 Pull out reduction shift shaft 6 together with fork 7 and sleeve 8 NOTE For this removal be sure to place front drive fork shaft at 4WD position 17 Remove rubber plug 5 as well TRANSFER 4WD 7D 7 18 Remove locating spring bolt 1 with washer 2 if equipped spring 3 and ball 4 for front drive shift 19 Pull out front drive shift fork 6 amp shaft 5
33. gear for runout 2 If adjustment is impossible replace drive bevel gear amp pinion set or differential carrier Replace drive bevel gear amp pinion set or differential case 7E 18 DIFFERENTIAL FRONT 11 Upon completion of gear tooth contact check in step 9 caulk flange nut 2 with caulking tool 1 and hammer 12 Clean mating surfaces of both housing and carrier and apply sealant A to housing side evenly A Sealant 99000 31110 13 With differential assembly installed in housing position it with 2 reamer bolts 2 and then install other 6 bolts 1 14 Torque all bolts to specification Tightening torque Differential carrier bolt a 23 N m 2 3 kg m 17 0 Ib ft 15 Install front drive shaft Tightening Torque Specification Fastening part Se fa T Air niet union Actuator bracket bolts Bevel gear bolis Bearing cap bolis o 60 45 Lock plate bolis Front differential carrier bolts DIFFERENTIAL FRONT 7E 19 Required Service Material Recommended SUZUKI product Thread lock cement THREAD LOCK CEMENT SUPER 1333B _ Bevel gear bolts Herd ee Lithium grease SUZUKI SUPER GREASE A Oil seal lips EE e0028010 ee Sealant SUZUKI BOND NO 1215 e Front differential drain and filler plug 99000 31110 e Mating surface of differential housing on e Air inlet union Special Tool 09900 20606 09900 20701 09913 61510 09913 75510 Dial gauge Magnetic stand Bearing puller Bearing
34. gets off center support and that will make it impossible to align fluid holes with bolt holes 11 Tighten center support bolts by certain amount at a time till specified tightening torque is obtained Tightening torque Center support bolt 26 N m 2 6 kg m 19 0 Ib ft 12 Install direct clutch assembly by aligning splines in direct clutch cylinder with planetary sun gear PT I NOTE N Ends of splines in direct clutch cylinder and planetary IE bat ae p Pr a sun gear should come almost in match f inst eee RN 13 Apply grease to forward clutch rear No 1 race 1 thrust rear bearing 2 thrust bearing rear planetary ring race 3 and install thrust bearing planetary ring race 3 to direct clutch cylinder and forward clutch rear No 1 race and thrust bearing to forward clutch hub 14 Install forward clutch assembly by putting all lugs of direct clutch disc hub together and matching them with groove cut in direct clutch input hub and at the same time aligning splines in forward clutch hub with inner shaft NOTE Use care not to let forward clutch rear No 1 race and thrust bearing installed to forward clutch hub fall off 7B1 56 AUTOMATIC TRANSMISSION 4 A T 15 When clutch disc and plate have been replaced check height difference between forward clutch input shaft and transmission case 1 by measuring as shown in the figure Standard height difference a About 2 0 mm 0 079 in NOTE
35. installer 09913 85230 09922 66020 09922 75222 09924 74510 Bearing removing jig Flange holder Preload adjuster Installer attachment 09925 18011 09926 68310 09926 78311 09930 40113 Bearing installer Bearing installer Bevel pinion mounting Rotor holder dummy 7E 20 DIFFERENTIAL FRONT 09930 40120 09927 66010 J23082 01 09944 66020 09944 76010 Attachment Oil pump aligner Bearing installer Differential carrier holder 09951 16060 09951 18210 09913 65135 09918 18110 Lower arm bush remover Oil seal remover amp Bearing puller Air pressure regulator installer No 2 DIFFERENTIAL REAR 7F 1 SECTION 7F DIFFERENTIAL REAR CONTENTS General Description ssassasnnnnnnennnenvevevnenennr 7F 2 Differential side bearing rrrnrnnnnnnnrnnn 7F 9 Unit Repair ainen ie aaia 7F 3 Drive bevel pinion nrsrseorrrnerrrrrverennn 7F 10 Disassembling Te EE 7F 3 Assembling Go NE EEE 7F 14 Component Inspection ceeeeeeeeeeeeeeeeee 7F 6 Tightening Torque Specification 7F 18 Sub Assembly Adjustment and Required Service Material 0008 7F 18 Reassembly 0 eee eradan A Ee 7F 6 Special TOOl rsesernrnevnenennvnenennvnennvnvnevnvnennvnn 7F 19 Differential carrier cccccccsssssseeeeeeeeeeees 7F 6 Differential CaSe rrrrrnrrnrnnrnnvnrnsrnennvnnnern 7F 6 7F 2 DIFFERENTIAL REAR General Description The differential assembly using a hypoid bevel pinion and gear
36. is installed to the rear axle It is set in the conven tional type axle housing The reduction ratio and the differential case vary depending on transmission or engine type The differential assembly is decisive in that the drive power is concentrated there Therefore use of genuine parts and specified torque is compulsory Further because of sliding tooth meshing with high pressure between bevel pinion and gear it is mandatory to lubricate them by hypoid gear oil 22 22 13 1 Differential left case 4 differential pinion type 13 2 Differential left case 2 differential pinion type 14 1 Differential right case 4 differential pinion type 14 2 Differential right case 2 differential pinion type DIFFERENTIAL REAR 7F 3 Unit Repair Disassembling Unit 1 Hold differential assembly securely and put identification marks on differential side bearing caps 6 2 Take off differential side bearing lock plates 4 and differen tial side bearing caps 6 by removing their bolts and then take out bearing adjusters 5 side bearing outer races and drive bevel gear with differential case 1 Differential carrier 2 Drive bevel gear assembly 3 Differential case A Identification mark 3 For 2 differential pinion type remove differential side gear pinion gear and pinion shaft a With aluminum plates 4 placed on vise first grip differen tial case with it and remove bevel gear 3 by removing its bolts 1
37. new adapter gasket to transmission case and tighten adapter case bolts to specified torque Tightening torque Adapter case bolt a 35 N m 3 5 kg m 25 5 Ib ft AUTOMATIC TRANSMISSION 4 A T 7B1 63 43 For J20 and H25 engines perform the following procedures J20 and H25 engines a Clean mating surface of transmission case 1 and adapter case 2 and apply sealant A to adapter case 2 A sealant 99000 31110 b Tighten adapter case bolts to specified torque Tightening torque Adapter case bolt a 42 N m 4 2 kg m 30 Ib ft 1 Adapter case 44 Apply A T fluid to new O ring and install it to vehicle speed sensor 1 and then install vehicle speed sensor 1 to adapter case 2 45 After turning manual shift shaft fully rearward turn it back by 2 notches and set it to N range Then install transmission range switch lock washer and set nut and tighten set nut After tightening it bend claws of lock washer Tightening torque Manual shift shaft set nut a 4 N m 0 4 kg m 3 0 Ib ft 46 With neutral reference line 1 and cut groove 2 in switch aligned tighten lock bolt Tightening torque Transmission range switch lock bolt b 5 5 N m 0 55 kg m 4 0 Ib ft 7B1 64 AUTOMATIC TRANSMISSION 4 A T 47 Confirm that torque converter is fully fitted in transmission Confirmation can be done by measuring dimension between end surface of housing case 2 and drive plate instal
38. or clutch plate is worn 15 Remove oil tubes NOTE Refer to the figure for order of their removal 16 Remove coupler from solenoid valve 1 AUTOMATIC TRANSMISSION 4 A T 7B1 7 17 Remove oil strainer 1 18 Remove valve body 2 mounting bolts as shown in the fig ure 19 Lift valve body 1 and disconnect A T throttle cable 2 from throttle cam 2 And remove valve body 20 Disconnect throttle cable 3 from case 4 21 Remove accumulator pistons 1 by blowing air into holes indicated in the figure NOTE Hold accumulator piston 1 with shop cloth while blow ing 22 Place transmission upright as shown in the figure NOTE 400 mm e To prevent transmission case from getting damaged un protect its contacting surface with stand by using shop cloth or the like e A stand of such size as shown in the figure will facili tate work 7B1 8 AUTOMATIC TRANSMISSION 4 A T 23 Check top surface level of forward clutch 2 against case 1 for reassembly 24 Remove forward clutch NOTE Confirm direction of bearing and bearing race for reas sembly 25 Remove direct clutch 1 26 Remove parking rod 1 and parking pawl 2 27 Remove 2 bolts 1 from valve body side to remove center support 28 Remove center support assembly 1 AUTOMATIC TRANSMISSION 4 A T 7B1 9 29 Remove retaining ring 1 planetary gear assembly and leaf spring NOTE e Use care not to cause
39. piston outer ring from brake piston AUTOMATIC TRANSMISSION 4 A T 7B1 19 6 Unsnap seal ring 1 7 Remove 2 seal rings 1 NOTE Be careful not to open seal ring more than necessary INSPECTION e Measure free length of piston return spring Standard free length of piston return spring 16 12 mm 0 635 in J20 engine 15 10 mm 0 594 in G16 and H25 engines ASSEMBLY Install each component by reversing removal procedure and not ing the following points e When installing rear seal ring use care not to open it too wide e Apply A T fluid to O ring disc etc before installing them e Opening of retaining brake front ring 2 and projection 1 of O D case should be matched e When installing each component refer to the first figure of OVER DRIVE CASE SIDE in this section e Install cushion brake plate 1 so that it warps convexly As a final step measure clearance between retaining brake front ring and brake backing plate again Standard clearance between retaining brake front ring and brake backing plate 0 56 1 38 mm 0 022 0 054 in G16 and J20 engines 0 40 1 38 mm 0 016 0 054 in H25 engine 7B1 20 AUTOMATIC TRANSMISSION 4 A T Forward clutch AT 1120 engine BI 19 and H25 engines AUTOMATIC TRANSMISSION 4 A T 7B1 21 DISASSEMBLY 1 After removing retaining ring 1 remove direct clutch input hub 2 and forward clutch hub 3
40. position as shown in the figure e Try to turn scissors gear against main shaft low and reverse gear It should feel light when turned in A direction but heavy when turned in B direction e Play of scissors gear against main shaft low or reverse gear in A B direction should be about half of tooth width as shown in the figure If any faulty condition is noted remove snap ring open up assem bly unit and check that all components are installed at proper positions If all components are positioned properly and yet faulty condition exists replace the low reverse gear assembly dude fate Gee AN VGA GS AAS on 1 Main shaft low or reverse gear 2 Scissors low or reverse gear spring 3 Scissors low or reverse gear 4 Snap ring 5 Pin Main gear side 6 Pin scissors gear side MANUAL TRANSMISSION TYPE 1 7A 17 Upper Case and Shifter e Using feeler gauge check clearance between fork 2 and sleeve 1 and replace those parts if it exceeds limit Clearance a between fork and sleeve Service limit 1 0 mm 0 039 in Insert each gear shift shaft into case and check that it moves smoothly If it doesn t correct by using oilstone reamer or the like e Check gear shift shaft for excessive wear and correct or replace a necessary 1 Locating groove 2 Yoke portion e Check free length of each locating spring 1 and replace if it nd ae N is below servic
41. shown in figure using workbench 2 or the like 35 Apply sealant evenly to front case side of intermediate case 1 as shown A Sealant 99000 31110 a 1 2 mm 0 047 in 36 Clean mating surface of front case 1 and install it to inter mediate case MANUAL TRANSMISSION TYPE 3 7A2 45 37 Fix C rings 1 2 to bearings as shown in the figure Special tool A 09900 06107 38 Clean mating surface of input shaft bearing retainer 1 and apply sealant evenly to input shaft bearing retainer 1 B Sealant 99000 31110 a 1 2 mm 0 047 in 39 Using new input shaft bearing retainer bolt install input shaft bearing retainer 1 Tightening torque Input shaft bearing retainer bolt a 17 N m 1 7 kg m 12 5 Ib ft 40 Insert gear shift inner shaft 1 and gear shift inner lever 2 to rear case 4 41 Drive spring pin 8 into gear shift inner lever 2 using spe cial tool Special tool A 09922 85811 7A2 46 MANUAL TRANSMISSION TYPE 3 42 Clean mating surface of rear case 1 and apply sealant evenly to rear case side of intermediate case 2 A Sealant 99000 31110 a 1 2 mm 0 047 in 43 Install rear case 1 to intermediate case 2 With tip end of gear shift shaft inner lever 3 hooked on head of gear shift shaft 4 Tighten case bolts to specified torque Tightening torque Rear case to intermediate case bolt a 37 N m 3 7 kg m 27 0 Ib ft
42. sleeve and hub assembly 1 onto shaft Special tool C 09913 84510 15 Fit large circlip 16 Install needle bearing Counter shaft 1 Install pin 6 friction gear 5 friction gear spring 4 friction gear retainer 3 and circlip 2 to counter shaft 1 in that order 2 Press fit front bearing 1 and fit circlip Special tool A 09913 84510 2 Counter shaft 7A 26 MANUAL TRANSMISSION TYPE 1 MN Y Urry O_o E 322 anse Wy MM J 3 With shaft inserted into case install center bearing outer race 1 on it and then press fit countershaft 2 by using special tool and hammer Meanwhile case should be sup ported on wood blocks Special tool B 09951 16080 4 Press fit reverse gear 1 and then 5th gear 2 NOTE When press fitting hold counter shaft 4 as shown in the figure with its front end set on special tool Special tool C 09913 80113 D 09944 66010 3 Lower case 5 Install bearing plate 1 applying thread lock cement A to their thread part of bolts A Cement 99000 32020 Tightening torque Bearing plate bolt a 6 N m 0 6 kg m 4 0 Ib ft 6 Install reverse idle gear 3 together with needle bearing 2 and thrust washer 1 on reverse idle gear shaft 4 and fix them with bolt 5 from outside of case NOTE Be sure to use aluminum washer for bolt Tightening torque Reverse idle gear shaft bolt b 23 N m 2
43. sure to apply sealant to mating surface of gear shift lever case 2 for its final installation C Cement 99000 32110 Tightening torque Control lever locating bolt a 17 N m 1 7 kg m 12 5 Ib ft Sub Assembly Input shaft assembly 1 Bring bearing 1 so that its groove for C ring is in the front of input shaft 2 and press fit with special tools and press Special tool A 09940 51710 B 09924 07720 C 09924 07710 2 Select circlip 1 that will make thrust clearance of bearing 0 1 mm 0 0039 in or less and install it Circlip thickness specification 2 35 2 40 mm 0 0925 0 0945 in 0867 D 2 25 2 30 mm 0 0886 0 0905 in TG 240 2 45 mm 0 0945 0 0965 in 2 30 2 35 mm 0 0906 0 0925 in MANUAL TRANSMISSION TYPE 3 7A2 27 3 Install roller bearing 1 to input shaft 2 Main shaft assembly NOTE e Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear e Use new circlips on shaft for installation Don t reuse circlips 1 Assemble high speed synchronizer hub 3 sleeve 4 springs 1 and keys 2 according to the following proce dure a Install synchronizer springs 1 and synchronizer keys 2 to high speed synchronizer hub 3 as shown in figure b Slide hub 3 in sleeve 4 so that chamfered side of sleeve 4 and small diameter boss side of hub 3 face opposite as shown in figure al
44. then put in inter lock ball 3 NOTE e Note that high speed gear shift shaft 2 can t be inserted unless reverse gear shift shaft 1 is placed at neutral position e When inserting high speed gear shift shaft 2 use care not to drop interlock pin 3 With both reverse and high speed gear shift shafts placed at neutral position insert low speed gear shift shaft 1 into case and fix fork with spring pin Then apply sealant to rub ber plug 2 and fit it in A Sealant 99000 31110 MANUAL TRANSMISSION TYPE 1 7A 29 4 Confirm that interlock system operates properly by checking the following e When shifted to low position or 2nd position shifting of 3rd 4th speed or 5th Rev speed is not available 1 Low speed gear shift shaft Low position 2 High speed gear shift shaft Neutral 3 Reverse gear shift shaft Neutral e When shifted to reverse position or 5th position shifting of 1st 2nd speed or 3rd 4th speed is not available rage Us a 1 Low speed gear shift shaft Neutral 2 High speed gear shift shaft Neutral 3 Reverse gear shift shaft Reverse position 5 Install locating balls and locating springs and then set wash ers and bolts Tightening torque Locating spring bolt a 28 N m 2 8 kg m 20 0 Ib ft 7A 30 MANUAL TRANSMISSION TYPE 1 Transmission Unit 1 Put main shaft input shaft assembly 7 into lower case 6 apply oil to component parts and che
45. toward bearing Special tool D 09925 18011 E 09940 53111 F 09951 26010 12 Install fork to corresponding shift shaft 13 Fit sleeve to front drive clutch hub 1 synchronizer spring 6 with synchronizer outer ring 3 center cone 4 and syn chronizer inner ring 5 When installing note that front drive clutch hub 1 and sleeve 2 have specific installing direc tion A Thick Front side B Thin Rear side C Oil groove Rear side TRANSFER 4WD 7D 15 14 Install front drive fork shaft 5 assembly and sleeve 7 amp hub 8 together into center case all at once Then put locat ing ball 4 and spring 3 also into case and tighten locating spring bolt 1 with washer 2 if equipped to specified torque A Cement 99000 32020 Tightening torque Locating spring bolt a 26 N m 2 6 kg m 19 0 Ib ft 6 Shift fork 9 Output rear shaft 15 With the outer ring 5 spring 4 if equipped cone 6 and inner ring 7 put together and installed to sprocket gear 2 as shown in figure install them together with chain 3 to out put rear shaft 1 16 Install steel ball 1 to output rear shaft 6 front side ball hole between output rear shaft No 2 bearing position and speed ometer drive gear position 17 Install needle bearing 3 to sprocket gear 2 ER 18 Install bush 4 to sprocket gear 2 with aligning sprocket w gear ball hole 5 to steel ball 1 z A
46. 0 01181 in NOTE Measure with torque converter installed 7B1 12 AUTOMATIC TRANSMISSION 4 A T e Check side clearance between inner gear outer gear and pump body Side clearance between inner gear outer gear and pump body Standard 0 02 0 05 mm 0 0008 0 0019 in Service limit 0 1 mm 0 0039 in ASSEMBLY Assemble each component by reversing removal procedure and noting following points e Before installing inner gear and outer gear to pump body apply A T fluid to them e When installing pump cover use care so that its splined part will not cause damage to oil seal and use specified torque to tighten it to pump body Tightening torque Oil pump bolt a 7 5 N m 0 75 kg m 5 5 Ib ft e When installing O ring and oil seal apply enough A T fluid to them and fit them securely in groove e After installation check that inner gear turns smoothly by making use of torque converter e When installing seal ring it should not be opened more than necessary e Fit claws of seal ring securely AUTOMATIC TRANSMISSION 4 A T 7B1 13 Overdrive Planetary gear side DISASSEMBLY 1 With overdrive O D clutch cylinder 1 held stationary turn O D input shaft 2 clockwise to check that it turns smoothly and then counterclockwise to check that it locks A Rotates B Locks 7B1 14 AUTOMATIC TRANSMISSION 4 A T 2 Remove O D planetary gear assembly 1 3 With O D clutch assembly
47. 0 25010 8 While tightening flange nut gradually with flange holder spe cial tool and power wrench 4 10 magnification 1 set preload of pinion to specification NOTE e Before taking measurement with spring balance 3 or torque wrench 4 check for smooth rotation by hand e Bearing preload can be measured roughly by pinion rotating angle which is due to arm weight of flange holder installed in flange Refer to following page for further information e Be sure to tighten gradually and carefully till specified starting torque is obtained Turning back overtight ened flange nuts should be avoided Pinion bearing preload 9 0 17 0 kg cm 7 8 14 7 Ib in Spring measure reading 1 8 3 4 kg 4 0 7 5 Ib Special tool A 09922 75222 H 09922 66020 2 Socket wrench Assembly Unit 1 Apply sealant A to thread part of air inlet union 2 and install it to differential carrier 1 Tighten it to specified torque A Sealant 99000 31110 Tightening torque Air inlet union a 13 N m 1 3 kg m 9 5 Ib ft 2 Place bearing outer races on their respective bearings Used left and right outer races are not interchangeable and install case assembly in carrier 3 Install side bearing adjusters on their respective carrier making sure adjusters are threaded properly 7E 14 DIFFERENTIAL FRONT 4 Align match marks 1 on cap and carrier Screw in 2 side bearing cap bolts
48. 09922 85811 4 Likewise drive spring pin 2 into gear shift lever 3 as far as the position shown in the figure CAUTION When driving spring pin 2 use care not to damage gear shift lever case 1 Special tool A 09922 85811 5 Remove case plug 7 6 Pull out gear shift shaft 4 from gear shift lever case 1 and take out gear shift lever 3 7 Remove gear shift lever bush 8 Transmission Unit 1 Remove clutch release bearing 1 release fork 2 and clutch housing 3 7A2 8 MANUAL TRANSMISSION TYPE 3 2 Remove back up light switch 1 3 Remove return spring low bolt 1 and return spring reverse bolt 2 4 Remove transmission to transfer bolt 1 5 Disconnect gear shift inner lever edge 2 from gear shift shaft 4 and remove rear case 3 tapping transmission rear case s end by plastic hammer 6 Drive spring pin 1 out by using special tool and then remove gear shift inner shaft 2 and gear shift inner lever 3 from rear case Special tool A 09922 85811 MANUAL TRANSMISSION TYPE 3 7A2 9 7 Remove input shaft bearing retainer 1 8 Remove C ring 1 of input shaft bearing and C ring 2 of counter shaft front bearing Special tool B 09900 06107 9 Tapping transmission front case 1 flanges with plastic ham mer remove transmission front case 10 Set transmission intermediate case 4 on vise 5 securely NOTE Use aluminum plates 6 betw
49. 12 1 2 shift valve DISASSEMBLY 1 Take out 6 valve body balls 1 7B1 46 AUTOMATIC TRANSMISSION 4 A T 2 With 3 2 kickdown control valve plug 1 pressed with fin ger take out needle roller 2 with magnet 3 Then remove 3 2 kickdown control valve plug 1 clutch sequence valve and reverse brake sequence valve spring 3 With shift valve plug 1 pressed with finger take out shift valve retainer 2 with magnet and then remove shift valve plug 1 and 3 4 shift valve spring 4 Remove 2 plate bolts Then remove rear upper valve body plate 1 and rear upper valve body gasket and take out 1 2 shift valve and shift valve spring 5 With shift valve plug 1 pressed with finger remove valve retainer with magnet 2 and then remove shift valve plug 1 2 3 shift valve and shift valve spring AUTOMATIC TRANSMISSION 4 A T 7B1 47 ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points e Coil outer diameter and free length of each valve spring should be as listed below Be sure to use each one of correct size Coil outer diameter and free length of each valve spring Name of spring Outer diameter Free length Reverse brake 9 10 mm 37 55 mm sequence valve spring 0 358 in 1 478 in 1 2 shift valve spring 8 29 15 mm 2 3 shift valve spring 0 in 1 147 in 3 4 shift valve spring e Use new rear upper valve body gasket e
50. 15 0 35 mm 0 006 0 013 in Limit 1 0 mm 0 039 in e Check diameter of main shaft 1 needle bush 2 and thick ness of main shaft 1 needle bush 2 flanges as shown in the figure If measured value is out of specification replace them or it Main shaft needle bush specification diameter and thickness 37 984 38 000 mm em 34 984 35 000 mm 7 N 3 955 4 195 mm 0 1558 0 1651 in C 4 80 5 20 mm 38 985 39 000 mm ee ee MANUAL TRANSMISSION TYPE 2 7A1 21 e Using V blocks 1 and dial gauge 2 check runout If runout exceeds limit below replace main shaft 3 Main shaft runout limit 0 06 mm 0 0023 in e Using cylinder gauge 1 check inside diameter of each gear If its inside diameter exceeds specification replace it Inside diameter of gear Standard 44 015 44 040 mm 1 7329 1 7 in ene onan eee e Check chamfered part of each sleeve for damage and exces sive wear and replace as necessary e Check each synchronizer key and synchronizer spring and replace as necessary e Check splined portions and replace parts if excessive wear is found e Check 2nd gear 1 thrust clearance by using thickness gauge 2 If clearance is out of specification repress fit or replace defective part 2nd gear thrust clearance Standard 0 10 0 25 mm 0 004 0 009 in e Check low gear 1 thrust clearance by using thickness gauge 2 If c
51. 16 Clamp wiring harness 3 and breather hoses 4 securely CAUTION Fill specified amount of gear oil to transmission and transfer after remounting transmission and transfer assembly to vehicle 1 Transmission assembly 2 Transfer assembly 4WD model Extension case 2WD model MANUAL TRANSMISSION TYPE 1 7A 33 Tightening Torque Specifications kom bt 23 23 17 0 65 2 200 s 35 35 Gear shift case bolts ETG 2 23 23 28 28 Required Service Material Recommended SUZUKI product KE par aa Lithium grease SUZUKI SUPER GREASE A e Oil seal lips 2 sysem Thread lock cement THREAD LOCK CEMENT SUPER 1333B e Shift control lever locating bolts 99000 32020 e Reverse gear shift limit bolt Counter shaft bearing plate bolts Sealant SUZUKI BOND No 1215 Mating surface of gear shift lever case 99000 31110 Rubber plug for interlock ball bore Upper case mating surface Mating surface of input shaft bearing retainer Input shaft retainer bolts Rear case mating surface 7A 34 MANUAL TRANSMISSION TYPE 1 09912 34510 Case separator 09913 75520 O D 60 5 mm Bearing installer 09925 18011 Bearing installer Special Tool 09913 60910 Bearing Gear puller 09913 80113 Bearing installer 09927 08210 Shaft remover 09913 61510 Bearing puller 09913 84510 Bearing installer 09944 66010 Wheel hub knuckle oil seal installer 09913 75510 O D 70 5 mm Bearing in
52. 18 8 35 N m 3 5 kg m o Fa 16 AH 22 his338 23 N m 2 3 kg m C 24 1288 ss la Oi 29 18 8 35 N m 3 5 kg m 32 8 13 Nm SH 7 1 3 kg m V2 28 Tes 14 146 1 Gear shift control lever knob 14 Spring pin 27 Reverse gear shift limit spring 2 Gear shift control lever 15 Roller 28 Reverse gear shift limit yoke 3 Clamp 16 Gear shift lever case 29 Gear shift arm 4 Lower gear shift fork 17 Case seat 30 Gear control lever bush 5 High gear shift fork 18 Select return spring bolt 31 Plug 6 5th reverse gear shift fork O 19 Select return spring 32 Gear shift case bolt Apply grease 99000 25010 to all around part of spring 7 Lower gear shift shaft O 20 Select guide pin 33 Shift lever case plate screw Apply grease 99000 25010 to all around part of pin 8 High gear shift shaft 21 Select return spring inner 34 Control lever locating bolt AGH Apply grease 99000 25010 to all around part of spring Apply thread lock 99000 31110 to all around thread part of bolt 9 5th reverse gear shif shaft 22 Reverse gear shift limit bolt 35 Lock washer bolt 10 Plug 23 Breather hose 36 Rubber plug Apply sealant 9900 31110 to mating surface to rubber plug 11 Gasket 24 Gear shift shaft 37 Gear shift case plate 12 Locating spring 25 Case plug Q Tightening torque MANUAL TRANSMISSION TYPE 1 7A 5 Input and Counter Shaft Components A 29 44 57 8 23 N m 2 3 kg m 1
53. 18011 7A 24 MANUAL TRANSMISSION TYPE 1 7 Fit sleeve 4 to reverse hub 3 place 3 synchronizer keys 2 in it and then set synchronizer springs 1 Refer to the figure for proper installing direction of hub 3 sleeve 4 and springs 1 Also note that key 2 has specific installing direction A Reverse side thin B 5th side thick C Key position D 5th side thick 8 Set steel ball and bearing washer 2 and insert reverse gear bush 3 needle bearing 4 and reverse gear 5 9 Press fit reverse sleeve and hub assembly 1 with special tool and press Special tool B 09925 18011 2 Reverse gear 10 After setting large circlip 2 install 5th speed synchronizer ring needle bearing 5th gear 4 steel ball 5 and washer 6 NOTE Washer should be installed with its oil slot side facing gear 1 Sleeve and hub assembly Bush 3 11 Press fit bearing 1 with special tool and press Special tool B 09925 18011 2 5th gear 4 Sleeve and hub assembly MANUAL TRANSMISSION TYPE 1 7A 25 12 Fit small circlip 13 Fit sleeve 4 to high speed hub 3 place 3 synchronizer keys 2 and set synchronizer springs 1 as shown in the fig ure Neither sleeve nor key has specific installing direction A 4th side thin B Key position 14 Install needle bearing 3rd gear 3 and 3rd synchronizer ring 2 Then using special tool and press press fit high speed
54. 2 7A1 39 24 Apply grease to locating roller No 2 1 and install roller 1 to reverse gear shift shaft 2 A Grease 99000 25010 25 Assemble reverse gear shift link assembly 26 Insert reverse gear shift shaft 2 into reverse gear shift link assembly and intermediate case while holding locating roller No 1 1 with magnet 3 27 Supporting locating roller No 1 1 with magnet 3 insert reverse gear shift shaft 2 into reverse gear shift link and intermediate case 28 Fix with new circlip 1 to reverse gear shift shaft by using rod or the like and hammer 29 Drive pin into reverse gear shift link 1 and shaft 2 by using special tool Special tool C 09922 85811 7A1 40 MANUAL TRANSMISSION TYPE 2 30 Install reverse gear shift yoke 1 and 5th gear shift fork 2 as shown in the figure 31 Supporting ball 1 with magnet 3 as shown in the figure insert 5th gear shift shaft 2 to 5th gear shift fork 4 and reverse gear shift yoke 5 32 Supporting ball 1 with magnet 3 as shown in the figure insert 5th gear shift shaft 2 into intermediate case 4 33 Apply thread lock cement A to thread of fork bolt and tighten bolt to specification A Cement 99000 32020 Tightening torque 5th gear shift fork bolt a 20 N m 2 0 kg m 14 5 Ib ft 1 5th gear shift fork 34 Insert 5th reverse gear shift shaft 1 to reverse gear shift yoke and drive pin into shaft and yoke
55. 3 Ball 30 Bush 47 Synchronizer key Q Tightening torque 14 Circlip 31 Rear bearing 48 5th synchronizer key 15 Oil seal 32 Circlip 49 Reverse gear ME 16 Low gear 33 Bearing plate 50 Needle bearing NAN 17 Needle bearing 34 Bearing plate bolt 51 Bush Apply thread lock 99000 31110 to all around thread part of bolt 7A 6 MANUAL TRANSMISSION TYPE 1 Unit Disassembly Gear Shift Lever Case 4WD Model 1 Remove 4 screws with screwdriver and remove case plate 2 With case 1 supported with soft jawed vise remove select return spring bolt 10 with wrench NOTE Use aluminum plates between vise and case to protect case 1 against damage 3 Using spring pin remover drive out double spring pin 2 for gear shift arm 9 NOTE Double spring pin 2 can be driven out through the hole 14 after removing its plug 15 After removing the dou ble spring pin 2 apply sealant to the plug 15 and install it A Sealant 99000 31110 NOTE All spring pin except double spring pin 2 can be driven out only in such direction that it comes out toward the deeper side of the shift lever case 1 4 Drive out spring pin 4 for reverse gear shift limit spring 7 5 Drive out double spring pin 2 for gear shift lever 5 6 Pull out gear shift shaft 8 a little and take out gear shift arm 9 NOTE e Case plug may come off during above work e If it is not possible to take out gear shift arm in abo
56. 322 e Control lever locating bolts er o0032n0 Sealant SUZUKI BOND No 1215 e Transfer oil drain plug and level filler plug 99000 31110 e Mating surface of transmission cases e Gear shift shaft plug MANUAL TRANSMISSION TYPE 3 7A2 49 Special Tool 09913 50121 09913 75510 09940 51710 09940 54950 Oil seal remover Bearing installer Bearing installer Bearing installer O D 70 5 mm attachment 09913 75821 09924 84510 004 09925 78210 6 mm 09922 85811 4 5 mm Installer attachment Bearing installer adapter Spring pin remover Spring pin remover 09913 84510 09940 53111 09900 06107 09944 3601 1 Bearing installer Bearing installer Snap ring pliers Steering wheel remover Opening type 09924 07720 09924 07710 09944 78210 09913 85230 Synchronizer hub installer Synchronizer hub installer Bearing installer support Bearing remover tool 7A2 50 MANUAL TRANSMISSION TYPE 3 AUTOMATIC TRANSMISSION 4 A T 7B1 1 SECTION 7B1 AUTOMATIC TRANSMISSION 4 A T CONTENTS General Description rrnnnnnvenvennvennenvenennenn 7B1 2 Forward clulehuauvassraosposarnn 7B1 20 Torque Converter Diagnosis srrssvusavusnvnnnn 7B1 3 INES U CIRC g DE EE 7B1 24 Stator Assembly Freewheels c 0 7B1 3 Center Support uaaersnspasstddtedt 7B1 28 Stator Assembly Remains Locked Up 7B1 3 Planetary gears and output shaft 7B1 34 Do Not Replace Converter for Following Valve body assembly rrnrennrrrnn
57. 3TD62V 34100001 Xx JSAFTBO3V00200001 JS3TL52V 34100001 JSAFTB52V00200001 X JSAFTDO2V00200001 X JSAFTD62V00200001 X JSAFTD62V34200001 X JSAFTL52V0020000 X JSAFTL52V3420000 x JSAFTB83V00100001 x JSAFTD83V00100001 x Xx gt lt amp 6 o 2 gt gt lt 9 e gt ek e GRAND VITARA XL 7 units on and after the following vehicle identification numbers VINs x JSAHTX92V00170001 JSAHTX92V30170001 X JSAHTX92V34170001 X x JSAHTY92V00170001 X JS3TX92V 34170001 When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricant sealants etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product infor mation available at the time of publication approval And used as the main subject of description is the vehicle of standard specifications among others Therefore note that illustrations may differ from the vehicle being actually serviced The right is reserved to make changes at any time without notice SUZUKI MOTOR CORPORATION COPYRIGHT SUZUKI MOTOR CORPORATION 2002 Table of Contents Mannual Transmission Type 1 Mannual Transmission Type 2 TRANSMISSION CLUTCH AND Mannual Transmission TYPE 3 Transfer 4WD Differential Front Differential Rear Automatic Transmission 4 A T 7B1 DIFFERENTIAL MANUAL TRANS
58. 7 Bearing installer Snap ring pliers Opening type Q 09940 54950 Bearing installer attachment 09922 85811 4 5 mm Spring pin remover 09941 84510 Bearing inner remover MANUAL TRANSMISSION TYPE 3 7A2 1 SECTION 7A2 MANUAL TRANSMISSION TYPE 3 CONTENTS General Description saassasnannnnennnenveveneenen 7A2 2 Main shaft assembly rrrrrrrrnornonnnnrrrr 7A2 21 Identification of Transmission Type 7A2 2 Counter shaft and reverse idle gear 7A2 23 Transmission Components snnnnnnnnnnnnnn 7A2 2 Unit Assembly nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 7A2 25 Transmission Case Components 7A2 3 Gear Shift Lever Case rrrrrrrrrrrrrrrrrrrrrrnn 7A2 25 Input and Counter Shaft Components 7A2 4 Sub Assembly snrrvrvrnrnrvrvrvereverererererennn 7A2 26 Gear Shifter Components seein 7A2 5 Input shaft assembly rrvrrrrrrrrrrrnnnnn 7A2 26 Unit Disassembly nnnnnnnnnnvvvvvvnvnnnnnnnnnnnnnnnnner 7A2 7 Main shaft assembly snnnnnnnnnnvnnnnnnne 7A2 27 Gear Shift Lever CaSe 7A2 7 Counter shaft and reverse idle gear 7A2 33 Transmission Unit iuunsuustdet hvit 7A2 7 Input shaft bearing retainer and oil Sub Assembly rserrvrrvervnvrvrrvervvvrnervensrnene 7A2 16 SVT 7A2 33 Input shaft assembly rsvrvrrvrrververrenn 7A2 16 Transmission rear CASe rrrrnnrrrnnnnnnnn 7A2 34 Main shaft assembly ororororenrrenren 7
59. 7A 33 Counter Shaft and Main Shaft Inner Parts 7A 14 Special TOO lusira 7A 34 7A 2 MANUAL TRANSMISSION TYPE 1 General Description Identification of Transmission Type Check shape of transmission and identify transmission as type 1 or type 2 type 3 Wheather transmission type 2 or type 3 equipped with the vehicle it can be identified by transmission identification number 1 and proceed to applicable section Transmission identification Transmission Applicable sec number type tion Type2 Section 7At Type3 Section 7A2 B Fig for type 2 and type 3 transmissions MANUAL TRANSMISSION TYPE 1 7A 3 Transmission Case Components 6 8 20 N m 2 0 kg m 11 0 23 N m 2 3 kg m gr GP 9 8 23 N m 2 3 kg m 1 Transmission upper case 6 Back up lamp switch 11 Upper case bolt Apply sealant 99000 31110 to mating surface to other transmission case 2 Transmission lower case 7 O ring 12 Rear case bolt Apply sealant 99000 31110 to mating surface to other transmission case 3 Transmission rear case 8 Oil filter and drain plug Q Tightening torque Apply sealant 99000 31110 to mating surface to other transmission case 4 Clutch housing 9 Input shaft retainer bolt 5 Input shaft bearing retainer 10 Clutch housing bolt Apply sealant 99000 31110 to mating surface to transmission case 7A 4 MANUAL TRANSMISSION TYPE 1 Gear Shifter Components 34 8 17 N m 1 7 kg m 589 3
60. 925 78210 4 Apply sealant to new case plug 8 and drive it into lever case 1 A Sealant 99000 31110 4 Outer spring pin 6 Gear shift shaft 5 Clean mating surface of gear shift lever case 1 and case plate 2 and then apply sealant evenly to surface of gear shift lever case 1 A Sealant 99000 31110 6 Tighten screws to specified torque Tightening torque Gear shift lever case plate screw b 6 N m 0 6 kg m 4 5 Ib ft MANUAL TRANSMISSION TYPE 2 7A1 25 7 Install gear shift lever case 2 to transmission without using sealant for functional check 8 Install shift control lever and check to make sure that it shifts smoothly according to shift pattern as shown in the figure NOTE e Apply thread lock cement C to control lever locating bolts 1 when retightening e Be sure to apply sealant to mating surface of gear shift lever case 2 for its final installation C Cement 99000 32020 Tightening torque Control lever locating bolt a 17 N m 1 7 kg m 12 5 Ib ft Sub Assembly Input shaft assembly NOTE e Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear e Use new circlips on shaft for installation Don t reuse circlips 1 Bring bearing 1 so that its groove for circlip is in the front of input shaft 2 and press fit with special tool and press Special tool A 09940 51710 2 Select circlip 1 that wi
61. A2 16 Transmission intermediate case and Counter shaft amp Reverse idle gear 7A2 18 front case location of knock and Input shaft bearing retainer and oil plug EEE NE npaneaeenee ene 7A2 35 AM eee rete eee ere eee ere 7A2 18 Transmission Unit seseeeeeseteseeeereeeeseees 7A2 36 Transmission rear CaSe rrrrrrrrrnnnnnnrr 7A2 19 Tightening Torque Specification 7A2 48 Components Inspection ananannxxxxnnevevennn 7A2 20 Required Service Material nnnxxnnnnnnnnne 7A2 48 Sub Assembly rrrnnnnnnnnnnnnnnnnnnrnvnvvnnnnnenee 7A2 20 Special TON aan 7A2 49 Input Shaft Assembly rrrnnrnnonnvrnvnnnr 7A2 20 7A2 2 MANUAL TRANSMISSION TYPE 3 General Description Identification of Transmission Type Refer to Section 7A in this manual Transmission Components 9 Low speed synchronizer sleeve Main shaft reverse gear MANUAL TRANSMISSION TYPE 3 7A2 3 Transmission Case Components 16 37 N m 3 7 kg m 19 U 37 N m 3 7 kg m 20 9 U 18 5 Nm 13 GJ 18 N m 1 8 kg m 1 85 kg i OG 1 85 kg m ho ER 22 Wd 8 37 N m 3 7 kg m 1 Clutch housing 9 Reverse gear shift arm bracket 17 Transmission rear case 2 Input shaft bearing retainer 10 Reverse gear shift arm bracket bolt 18 Main shaft oil seal Apply sealant 99000 31110 to mating Apply grease 99000 25010 to oil surface to transmission front case seal lip 3 Oil seal 11 Transmission intermedia
62. ANSMISSION TYPE 2 20 Remove reverse gear shift shaft 2 locating roller No 1 1 and reverse gear shift link component 3 by using magnet NOTE When pulling gear shaft 2 hold locating roller No 1 1 with magnet 4 to prevent it from falling 21 Disassemble reverse gear shift link component 3 by remov ing E rings 22 Remove locating roller No 2 1 from low gear shift shaft 2 by using magnet 3 23 Remove circlip 1 from low gear shift shaft 2 as shown in the figure 24 Remove bolt from low speed gear shift fork 1 25 Remove low gear shift shaft 2 and locating roller No 1 1 by using magnet 3 NOTE When pulling gear shaft 2 hold locating roller No 1 1 with magnet 3 to prevent it from falling MANUAL TRANSMISSION TYPE 2 7A1 13 26 Remove circlip 1 from high gear shift shaft 2 as shown in the figure 27 Remove bolt from high speed gear shift fork 1 28 Remove high gear shift shaft 2 high speed gear shift fork 1 and low speed gear shift fork 3 29 Check counter shaft 5th gear 1 thrust clearance by using thickness gauge 2 Counter shaft 5th gear thrust clearance Standard 0 10 0 30 mm 0 0040 0 0118 in 30 Remove circlip 1 from counter shaft 2 as shown in the fig ure 31 Remove 5th speed synchronizer dog by using special tool Special tool D 09941 84510 7A1 14 MANUAL TRANSMISSION TYPE 2 32 Remove synchronizer ring n
63. ANUAL TRANSMISSION TYPE 3 7A2 21 Main shaft assembly Check clearance a between synchronizer ring and gear width of index protrusion b in synchronizer ring key slot width c in high and low speed synchronizer hub and each chamfered tooth of gear and synchronizer ring and replace with new one if neces sary Also check gear tooth Clearance a between synchronizer ring and gear Main shaft 1st Standard 0 65 1 75 mm 0 026 0 069 in Service limit 0 5 mm 0 020 in 2nd Standard 0 65 1 75 mm 0 026 0 069 in Service limit 0 5 mm 0 020 in 3rd Standard 0 65 1 75 mm 0 026 0 069 in Service limit 0 5 mm 0 020 in Width of index protrusion b Main shaft 1st Standard 4 8 5 0 mm 0 189 0 197 in Service limit 4 5 mm 0 177 in 2nd Standard 5 7 5 9 mm 0 224 0 232 in Service limit 5 4 mm 0 213 in 3rd Standard 4 3 4 5 mm 0 169 0 1777 in Service limit 4 0 mm 0 157 in Key slot width c High and low speed synchronizer hub 1st Standard 9 0 9 1 mm 0 354 0 358 in 2nd Standard 9 0 9 1 mm 0 354 0 358 in 3rd Standard 8 0 8 1 mm 0 315 0 319 in e Measure width of high speed gear shift fork end a and groove width of high speed synchronizer sleeve b and then calculate clearance c as follows Clearance o h ri a If clearance exc
64. Apply oil to bearings 1 Bevel pinion 2 Rear bearing 8 Using special tool and plastic hammer drive oil seal 2 into differential carrier 1 till it becomes flush with carrier end Then apply grease A to oil seal lip A Grease 99000 25010 Special tool 1 09951 18210 9 While tightening flange nut gradually with special tool and power wrench 4 10 magnification 1 set preload of pin ion to specification NOTE e Before taking measurement with spring balance 3 or torque wrench 4 check for smooth rotation by hand e Bearing preload can be measured roughly by pinion rotating angle which is due to arm weight of flange holder installed in flange e Be sure to tighten gradually and carefully till specified starting torque is obtained Turning back overtight ened flange nuts should be avoided Pinion bearing preload 0 9 1 7 N m 9 0 17 0 kg cm 7 8 14 7 Ib in Spring measure reading with special tool 18 34 N 1 8 3 4 kg 4 0 7 5 Ib Special tool C 09922 75222 J 09922 66020 2 Socket wrench 7F 14 DIFFERENTIAL REAR Assembling Unit 1 Place bearing outer races on their respective bearings Used left and right outer races are not interchangeable 2 Install case assembly in carrier 3 Install side bearing adjusters on their respective carrier making sure adjuster are threaded properly 4 Align match marks 1 on cap and carrier Screw in 2 side
65. B 09922 66020 1 Bolt and nut 2 Socket wrench 3 Power wrench 4 10 magnification 9 Make mating marks 1 on drive bevel pinion and companion flange CAUTION Don t make mating mark on the coupling surface of the flange 10 Remove companion flange from pinion Use special tool if it is hard to remove Special tool C 09913 65135 11 Remove bevel pinion with front bearing and spacer from carrier If it is hard to remove screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on pinion DIFFERENTIAL FRONT 7E 5 12 Using special tools pull out differential side bearings Special tool D 09913 85230 13 With aluminum plates 3 placed on vise first grip differential case with it and remove bevel gear 2 by removing its 10 bolts 1 CAUTION Use care not to hold axle lock clutch part with vise Be sure to hold differential left case 14 Separate differential case assembly by removing 2 screws 2 and take out free axle hub side gears and shims from dif ferential left case 1 Differential left case 3 Axle lock clutch 15 Remove bevel pinion front bearing 2 by using bearing puller 3 and press 1 Drive bevel pinion 7E 6 DIFFERENTIAL FRONT 16 Drive out bevel pinion bearing outer races in differential car rier by hammering metal stick applied to them Components Inspection e Check companion flange for wear or dama
66. Er Rs a 2 19 Install synchronizer plate 1 Tightening torque Synchronizer plate screw a 10 N m 1 0 kg m 7 5 Ib ft B Cement 99000 32020 7D 16 TRANSFER 4WD 20 Using special tool press fit output rear shaft No 2 bearing 1 into output rear shaft It is necessary to place support base at lower end of shaft Special tool D 09925 18011 G 09926 68310 21 After installing large size circlip 4 and steel ball 5 install speedometer drive gear 3 and secure it with small size cir clip 2 22 Install interlock steel ball 1 2 Front drive shift shaft TRANSFER 4WD 7D 17 23 Combine sleeve 8 to reduction shift shaft assembly 6 and install them into center case 9 Then put locating ball 4 and spring 3 also into case and tighten locating spring bolt 1 with washer 2 if equipped NOTE e Circumferential groove mark thicker rail side which works as shift stopper should be inside rear e Hub has no specific direction A Cement 99000 32020 Tightening torque Locating spring bolt a 26 N m 2 6 kg m 19 0 Ib ft 24 With sealant applied to rubber plug 5 insert it into hole in case NOTE When installing reduction shift shaft front drive shift shaft must be placed at 4WD position C Sealant 99000 31110 A Groove center case side 2 Washer 7 Shift fork 25 If friction ring 2 has been removed from counter shaft 1 press fit
67. For smooth installation of front case apply grease to counter shaft O ring e When mating front case make sure that input gear meshes with counter gear first C Sealant 99000 31110 35 Torque 9 front case bolts 2 to specification Tightening torque Front case bolt d 23 N m 2 3 kg m 17 0 Ib ft 36 Torque counter shaft plate fixing bolt 1 applied with thread lock cement to specification NOTE e After tightening bolts check input gear and output rear shaft for smooth rotation by hand at low and high speed position e Also check front drive shift for proper operation B Cement 99000 32020 Tightening torque Counter shaft plate bolt c 23 N m 2 3 kg m 17 0 Ib ft 37 Before assembling rear case 2 adjust clearance C select ing shim size as follows 3 Rear shaft bearing No 1 4 Rear shaft bearing No 2 A B C Clearance a Measure rear case 1 dimension A from mating surface to bearing bore bottom by using straightedge 2 and ver nier caliper Width of straightedge D plus A is obtained 7D 20 TRANSFER 4WD b Place straightedge on bearing No 2 2 securely and mea sure bearing height B from center case 1 mating sur face to No 2 bearing top CAUTION Bridging straightedge between No 2 bearing and output front shaft bearing brings misreading c Obtain clearance C in following calculation ae Os A D
68. Important WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instructions clearer WARNING This service manual is intended for authorized SUZUKI dealers and qualified service mechanics only Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver and passengers WARNING For vehicles equipped with a Supplemental Restraint Air Bag System e 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 service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precautions under On Vehicle Service in air bag system section before performing service on or aro
69. MISSION TYPE 1 7A 1 SECTION 7A MANUAL TRANSMISSION TYPE 1 CONTENTS General Description cccscceeeeeeeeeeeeeeeeeeeeeees TA 2 Low and reverse scissors gear Identification of Transmission Type 7A 2 assemblies if equipped eee 7A 16 Transmission Case Components 7A 3 Upper Case and Shifter rrrrrnrrrnnnnnnnnnvnene TA 17 Gear Shifter Components HP 7 A 4 Re CASO annen TA 17 Input and Counter Shaft Components 7A 5 Unit Assembly nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 7A 18 Unit Disassembly nnnnnnnnnevnnnnnnnnnnnnnnnnnnnnenevnrr 7A 6 Gear Shift Lever Case 4WD Model 7A 18 Gear Shift Lever Case 4WD Model 7A 6 Gear Shift Lever Case 2WD Model 7A 20 Gear Shift Lever Case 2WD Model 7A 7 Sub Assembly snrnnnrnnnnnnnnvvnnnnnnnvnnnnnnnnnnnn 7A 22 Transmission Unit ccc ccccccccccccccceeccce 7A 7 MANSELL pvr 7A 22 Sub ASsembly oo cecessesesesesseseesesesseseseeeerean 7A 11 Counter SHAM scascaccactorssninsievuessvevetetataataties 7A 25 ene EEE 7A 11 Upper case and shifter rernnererernrnrnen TA 27 Main shaft Lars 7A 12 Transmission Unit eceseeeseeeeeeeeeeeeeeeeeeees 7A 30 Upper case and shifter rrrrrnnnnnnnneenne 7A 14 Tightening Torque Specifications 7A 33 Component Inspection ssssseeee 7A 14 Required Service Material 00000
70. N 4 A T 7B1 41 2 Place new upper valve body gasket on lower valve body 5 assembly 0 9 Zo o o 1000009 8 8 00000 3 While holding upper valve body gasket and lower valve body 1 assembly together install it on rear upper valve body assembly 2 4 Tighten 3 bolts indicated in the figure temporarily 5 Turn over lower valve body assembly and tighten 4 bolts indi cated in the figure temporarily 6 Remove 2 bolts tightened temporarily in Step 1 NOTE Be careful not to damage gasket 7B1 42 AUTOMATIC TRANSMISSION 4 A T 7 Install lower valve body assembly 1 on front upper valve body 2 8 Tighten 3 bolts indicated in the figure temporarily 9 Turn over control valve lower body and tighten 5 bolts indi cated in the figure temporarily 10 Tighten bolts on upper valve body side to specified torque Tightening torque Upper valve body bolt 5 5 N m 0 55 kg m 4 0 Ib ft NOTE Tighten bolts by a certain amount of torque evenly and repeat it several times till specified torque is attained 11 Tighten bolts on lower valve body inside to specified torque Tightening torque Lower valve body bolt 5 5 N m 0 55 kg m 4 0 Ib ft NOTE Tighten bolts by a certain amount of torque evenly and repeat it several times till specified torque is attained AUTOMATIC TRANSMISSION 4 A T 7B1 43 12 After installing manual valve 3 install detent spring 2 and plate 1 and tighten detent s
71. ON TYPE 2 7A1 43 43 With tip end of gear shift shaft inner lever 1 hooked on head of gear shift shaft 2 insert gear shift inner shaft 3 into gear shift shaft inner lever 44 Apply cement A to inner gear shift shaft bolt plug and tighten them to specification A Cement 99000 32020 Tightening torque Gear shift shaft inner bolt a 39 N m 3 9kg m 28 5 Ib ft Gear shift shaft inner plug b 19 N m 1 9kg m 14 0 Ib ft 45 Tighten return spring low bolt and return spring reverse bolt Black color 1 NOTE Install return spring reverse bolt Black color 1 to left side of case Tightening torque Return spring reverse bolt Black color a 28 N m 2 8 kg m 20 5 Ib ft 7A1 44 MANUAL TRANSMISSION TYPE 2 46 Apply cement A to locating screw 1 and install locating ball 3 locating spring 2 and screw to rear case Free length a of locating spring Standard 22 1 mm 0 87 in Limit 21 4 mm 0 83 in A Cement 99000 32020 Tightening torque Locating screw a 19 N m 1 9 kg m 14 0 Ib ft 47 Install back up light switch with new gasket Tightening torque Back up light switch a 45 N m 4 5 kg m 32 5 Ib ft 48 Install clutch housing 3 and torque its bolts to specification Tightening torque Clutch housing bolt a 50 N m 5 0 kg m 36 5 Ib ft 1 Release bearing 2 Release fork MANUAL TRANSMISSION TYPE 2 7A1 45 Tightenin
72. OTE Be sure to use bearing holder for the purpose of protect ing lower bearing Special tool A 09944 66020 B 09951 16060 7F 10 DIFFERENTIAL REAR Drive bevel pinion To engage bevel pinion and gear correctly it is pre required to install bevel pinion to differential carrier properly by using adjusting shim as described on the followings Shown below is relative positions of bevel pinion differ ential carrier and mounting dummy Special tool A 09900 20606 B 09926 78311 C 09922 75222 D 09951 16070 E 09922 77250 4 differential pinion type F 09951 46010 4 differential pinion type a Pinion dummy height Attachment height a b Mounting dummy size 97 00 mm 3 81889 in 2 differential pinion type 102 00 mm 4 01575 in 4 differential pinion type d Differential carrier mounting distance a b c e Bevel pinion mounting distance Marked in shaft in mm f Shim size for mounting distance adjustment d e 1 Universal Joint flange P No 27110 60A00 DIFFERENTIAL REAR 7F 11 1 Install special tools with bearings and universal joint flange 2 to differential carrier 1 NOTE e This installation requires universal joint flange 2 not equipped with groove on flange periphery e This installation requires no spacer or oil seal Special tool B 09926 78311 F
73. aS Wak 38 Remove C ring 1 of counter shaft rear bearing using spe cial tool Special tool B 09900 06107 39 Remove counter shaft rear bearing from intermediate case using rod 2 and hammer and then remove counter shaft 3 NOTE This removal requires 2 persons One should hold counter shaft 3 and the other should remove bearing 1 using rod 2 and hammer MANUAL TRANSMISSION TYPE 3 7A2 15 40 Remove input shaft assembly 1 with 4th gear synchronizer ring from main shaft assembly 2 NOTE When removing input shaft be careful not to drop roller bearing 41 Remove C ring 1 of main shaft bearing using flat head screwdrivers 2 or the like and pull out main shaft assembly 3 NOTE If intermediate case 4 is engaged with bearing firmly tap front face of intermediate case 4 with plastic ham mer lightly as it will cause main shaft assembly 3 to come off forward 7A2 16 MANUAL TRANSMISSION TYPE 3 Sub Assembly Input shaft assembly Remove circlip of input shaft 1 and pull out bearing 2 with puller 3 and press CAUTION Sealed bearing must not be washed Replace it with new one when required Main shaft assembly 1 Remove circlip 1 from main shaft 2 using flat head screw drivers 3 or the like 2 Pull out 5th gear 1 main shaft bearing 2 low gear thrust washer 3 and low gear 4 with puller 5 and press 6 CO ess 3 Remove low gear syn
74. amp installer No 2 09944 66020 Bearing installer 09951 46010 Drive shaft oil seal installer 09951 16060 Lower arm bush remover Prepared by SUZUKI MOTOR CORPORATION 1st Ed Dec 2002 Printed in Japan 268
75. aph which should be read as follows Example When preload of bevel pinion is 2 6 kg 5 73 Ib acceptable composite preload of both pinion bearings and side bear ings should be between 2 8 and 3 2 kg 6 17 and 7 05 Ib 3 Universal joint flange 4 Socket with adapter NOTE Bearing preload can be checked roughly by using flange holder as shown in the figure In this measurement holder arm itself will work as balance weight and torque will be replaced with angle However flange should be rotated very slowly with hand support so as not to allow over revolution due to inertia Special tool E 09922 66020 A Pinion bearing starting torque range B Pinion bearing plus side bearing starting torque range NOTE Repeat side bearing adjustment until gear backlash and composite bearing preload are compatible within specifi cation if fail to obtain specified measurements first 7E 16 DIFFERENTIAL FRONT Drive bevel pinion bearing starting torque preload side bearing starting torque preload Degree 11 4 Degree 15 0 13 0 6 0 7 5 b 1 8 1 9 20 2 12 2 2 3 2 4 2 526 2 7 2 8 2 9 3 03 1 3 2 3 3 3 4 kg a rs 7 9 9 0 11 3 13 0 14 7 17 0 kg om Ib in Drive bevel pinion bearing starting torque preload 9 Torque bearing cap bolts to specification and install bearing lock plates Tightening torque Bearing cap bolt a 60 N m 6 0 kg m 43 5 Ib ft Lock plate bolt b
76. ase MANUAL TRANSMISSION TYPE 3 7A2 37 NOTE When fitting of intermediate case 1 and bearing is tight tap rear face of intermediate case 1 with plastic hammer lightly as it will cause main shaft assembly 2 to install 3 Fix bearing with new C ring 1 using special tool Special tool A 09900 06107 4 Align key slots of high speed synchronizer hub 1 and pro trusion of 4th gear synchronizer ring 2 and set input shaft assembly to main shaft assembly Check that input shaft assembly turns lightly 5 Fix with new C ring to counter shaft rear bearing 6 Install counter shaft 1 and rear bearing 2 to intermediate case 3 NOTE e When installing rear bearing 2 bring it so that its C ring side is at rear side of intermediate case as shown in figure e When fitting of intermediate case 3 and rear bearing 2 is tight tap outer race of rear bearing 2 lightly and evenly with plastic hammer 7A2 38 MANUAL TRANSMISSION TYPE 3 RA NNN T D 2 7 Install reverse idle gear 1 and shaft 2 1 8 Install main and counter shaft bearing 1 to intermediate case Tightening torque Main and counter shaft bearing retainer bolt a 18 N m 1 8 kg m 13 0 Ib ft 9 Set pin 1 and thrust washer 2 to counter shaft 10 Assemble counter shaft 5th gear 1 plate spring 2 circlip 3 5th amp reverse synchronizer sleeve 4 balk levers 5 synchronizer key spring 6
77. ase Components 15 GU 28 N m 2 8 kg m 23 U 35 N m 3 5 kg m a 10 21 G 19 N m 1 9 kg m 1333B 1 9 kg m 11 8 45 N m 4 5 kg m 5 DS 9 CSN Le A gt r D S lg 22 33 Q 17 N m 1 7 kg m Clutch housing 10 Main Counter shaft bearing plate 19 Interlock cam plug Apply thread lock 99000 32020 to all around thread part of plug 1 2 Input shaft bearing retainer 11 Back up light switch 20 Reverse link stay bolt 3 Gasket 12 5th reverse interlock cam comp 21 Bearing plate bolt 4 Oil seal 13 Return spring low bolt 22 Input shaft bearing retainer bolt Apply grease 99000 25010 to oil Apply thread lock 99000 32020 to all seal lip around thread part of bolt 14 Counter shaft gutter 23 Transmission case bolt 6 Oil drain plug 15 Return spring reverse bolt 24 Clutch housing bolt 7 Oil filter level plug O 16 Main shaft oil seal Q Tighting torque Apply grease 99000 25010 to oil seal lip 9 Transmission intermediate case 18 Interlock cam pin Apply sealant 99000 31110 to mating surface to transmission case MANUAL TRANSMISSION TYPE 2 7A1 5 Gear Shifter Components 5 amf3338 17 N m 1 7 kg m 6 azn i orm 0 6 kg m gea 19 N m 1 9 kg m 28 8 19 nm 1 9 kg m iw ao CE nit nN O S 29 S26 8 19 N m 1 9 kg m 23 35 13338 U 20 N m 2 0 kg m 1 Gear shift control lever knob 14 5th reverse gear shift shaft 27 Gear shift i
78. assembly and what is found through visual check of bearing and gear tooth etc after disassembly prepare replacing parts and proceed to reas sembly according to procedures as described below CAUTION e Bevel gear and pinion must be replaced as a set when either replacement becomes necessary e When replacing taper roller bearing replace as inner race amp outer race assembly Differential carrier For press fitting bevel pinion bearing outer races use special tools as shown in the figure CAUTION Perform press fitting carefully so as not to tilt outer race Special tool A 09924 74510 B 09926 68310 C 09913 75510 1 Differential carrier Differential case 1 Install differential gears 3 free axle hub 4 and washers 2 to left case 7 2 Install left case to right case 1 and tighten screws 8 5 Differential pinion shaft 6 Differential pinion DIFFERENTIAL FRONT 7E 9 3 Put bevel gear 1 on differential case 2 and fasten them with 10 bolts 3 by tightening them to specified torque Use thread lock cement A for 10 bolts 3 CAUTION Use of any other bolts than that specified is prohibited A Thread lock cement 99000 32020 Tightening torque Drive bevel gear bolt a 85 N m 8 5 kg m 61 5 Ib ft 4 Press fit side bearing 1 with special tool and press Special tool G 09944 66020 5 Install actuator 1 to differential case 2 NOTE Note that
79. at it locks and then counterclockwise to check that it turns smoothly A Rotates B Locks 7B1 38 AUTOMATIC TRANSMISSION 4 A T Valve body assembly 2 TCC solenoid valve 6 Spring 10 Lower valve body assembly 14 Intermediate coast modulator valve Solenoid valve No 2 7 Ball 11 Plate 15 Low coast modulator valve 4 Detent spring 8 Shift solenoid valve A amp B 12 Front upper valve body 16 By pass valve Solenoid valve No 1 AUTOMATIC TRANSMISSION 4 A T 7B1 39 DISASSEMBLY 1 Remove detent spring 2 plate 1 and manual valve 3 2 Remove bolts from upper valve body side 3 Remove bolts from lower valve body side 4 Separate upper valve body 2 and lower valve body 1 while pressing separator plate and valve body gasket against lower valve body 1 to prevent balls spring and others from coming out of valve body 7B1 40 AUTOMATIC TRANSMISSION 4 A T 5 Confirm that there are valve balls and plate as shown in the figures e Front upper valve body assembly 1 Throttle valve keep plate 2 Locating pin 3 Cut back valve retainer e Rear upper valve body assembly 1 Valve body ball 2 Needle roller e Lower valve body assembly 1 Bypass valve ASSEMBLY 1 Place separator plate and new lower valve body gasket on lower valve body assembly and tighten installation section of front upper valve body assembly with 2 bolts 1 temporarily AUTOMATIC TRANSMISSIO
80. ating surfaces of both cases coat mating surface 1 of rear case with sealant evenly and mate it with transmis sion itself A Sealant 99000 31110 8 Install 12 rear case bolts and torque them to specification Tightening torque Rear case bolt a 23 N m 2 3 kg m 17 0 Ib ft 1 Clutch housing 3 Clutch release bearing 4 Bolt 9 Install back up light switch 1 Tightening torque Back up light switch a 20 N m 2 0 kg m 14 5 Ib ft 10 Install gear shift lever case 4 temporarily to confirm switch function by checking the following e Back up light switch 1 should conduct when gear shift con trol lever 3 is at reverse position 11 After confirming switch function remove gear shift lever case 2 Ohmmeter 7A 32 MANUAL TRANSMISSION TYPE 1 12 Connect transfer assembly 2 to transmission assembly 1 and tighten its fastening bolts to specified torque Tightening torque Transfer to transmission bolt a 23 N m 2 3 kg m 17 0 Ib ft 13 With sealant applied to mating surface of transmission gear shift lever case 5 put it onto transmission and transfer assembly and torque bolts to specification A Sealant 99000 31110 Tightening torque Gear shift case bolt b 13 N m 1 3 kg m 9 5 Ib ft 14 Install breather hoses 4 for transmission and transfer and set clamps 15 Connect wiring harness 3 to each coupler of 4WD switch oth switch and back up light switch
81. bearing 3 main shaft bearing 4 and low gear 5 with puller 6 and press 7 3 Remove synchronizer ring and ball 1 MANUAL TRANSMISSION TYPE 2 7A1 17 4 Pull out low speed sleeve hub assembly 1 needle bearing and 2nd gear 2 from main shaft 5 Pull off synchronizer springs keys and low speed sleeve from hub 3 Puller 6 Remove circlip from front part of main shaft and pull out 3rd gear 1 needle bearing synchronizer ring and high speed sleeve hub assembly 2 3 Puller Counter shaft amp reverse idle gear 1 Remove circlip 1 from counter shaft Special tool A 09900 06107 2 Pull out bearing 3 from counter shaft by using puller 4 press 1 and rod diameter approx 22 mm 0 87 in 2 7A1 18 MANUAL TRANSMISSION TYPE 2 Input shaft bearing retainer and oil seal Remove oil seal 1 from bearing retainer 2 by using rod or the like as shown in the figure NOTE Unless oil seal is leaky or its lip is excessively hardened replacement is not necessary Transmission rear case 1 Remove counter shaft gutter 2 from transmission rear case 1 2 Take out oil seal 1 from rear case 2 3 Remove interlock cam plug 1 by using torx 2 MAG LAD GRETE AA at av ET my JAN WwW MANUAL TRANSMISSION TYPE 2 7A1 19 4 Remove pin by using special tool and a hammer Special tool A 09922 85811 5 Pull out interlock cam c
82. below and correct whatever neces sary carefully using reamer oilstone and the like wash it thoroughly and reassemble it Item to be checked is e Shift shaft should go into case smoothly 2 Insert shift shaft 1 as shown in figure while making sure that inner parts are in proper direction NOTE e Cut off portion 3 in shift shaft 1 should face down ward when installing shift shaft 1 e Shift lever 2 should be installed at the same time 3 Drive in spring pins 2 for gear shift lever 5 and shift arm 7 NOTE When driving in spring pins position their slits 180 30 apart Special tool A 09925 78210 4 Apply sealant to new case plug 8 and drive it into lever case 1 B Sealant 99000 31110 5 Apply grease to shift lever bush 9 and install it A Grease 9000 25010 3 Inner spring pin 4 Outer spring pin 6 Gear shift shaft 6 Install case plate 2 to gear shift lever case 1 and tighten screws to specified torque Tightening torque Gear shift lever case plate screw b 6 N m 0 6 kg m 4 5 Ib ft 7A2 26 MANUAL TRANSMISSION TYPE 3 7 Install gear shift lever case 2 to transmission without using sealant for functional check 8 Install shift control lever and check to make sure that it shifts smoothly according to shift pattern as shown in figure NOTE e Apply thread lock cement C to control lever locating bolts 1 when retightening e Be
83. case bolts to specification along with rear cover 8 if equipped and transfer damper bracket 9 Tightening torque Gear shift lever case bolt j 13 N m 1 3 kg m 9 5 Ib ft 2 Select return pin 3 Ball 4 Select return spring 49 Install gear shift control lever temporarily and check to make sure that it shifts to each shift position smoothly Also check shaft for rotation 50 Confirm 4WD switch 2 terminals are continuity at 4WD position 4H and 4L by using ohmmeter 1 TRANSFER 4WD 7D 23 51 For A T model confirm 4WD LOW switch terminals are con tinuity at 4WD LOW and Neutral position AL 52 Upon completion of above checks remove shift control lever Pull Ep r Tightening Torque Specification Tightening torque 55 170 Nm kgm gt Center case gutter bolt 808 Rear case plate bolt HE 08 Front case bolts 17 0 Counter shaft plate bolt Select return spring bolt For A T and TYPE 1 M T 35 Select return spring bolt For TYPE 2 and TYPE 3 M T 5 5 Gear shift lever case bolt Synchronizer plate screws Required Service Material Recommended SUZUKI product Mati Oper Number Lithium grease SUZUKI SUPER GREASE A e Oil seal lips and O rings ENO DNO Sette Thread lock cement THREAD LOCK CEMENT SUPER 1333B Center case gutter bolt 99000 32020 e Rear case plate bolt Locating spring bolt Countershaft plate bolt Synchronizer plate screws Sealant SUZUKI BOND No 1215 Rubber plug 99000
84. chronizer inner ring 1 synchronizer cone ring 2 synchronizer outer ring 3 pin 4 needle Na I aS bearing 5 and spacer 6 EG Hu i CCA I Ga AI ES f NEY MANUAL TRANSMISSION TYPE 3 7A2 17 4 Remove circlip 9 and pull out 2nd gear 2 needle bearing 5 2nd gear synchronizer outer ring 6 cone ring 7 inner ring 8 and low speed synchronizer sleeve hub assembly 1 together using puller 3 and press 4 5 Remove circlip 9 from front part of main shaft and pull out 3rd gear 1 needle bearing 8 3rd gear synchronizer outer ring 5 cone ring 6 inner ring 7 and high speed synchro nizer sleeve hub assembly 2 together using puller 3 and press 4 6 Remove high speed synchronizer sleeve from high speed synchronizer hub 2 7 Remove keys 1 and springs from high speed synchronizer hub 2 using flat head screwdriver 3 or the like as shown in the figure 8 Remove low speed synchronizer sleeve hub in similar man ner as steps 6 and 7 7A2 18 MANUAL TRANSMISSION TYPE 3 afl je MD Counter shaft amp Reverse idle gear 1 Remove circlip 1 from counter shaft Special tool A 09900 06107 2 Pull out counter shaft front bearing 3 from counter shaft by using puller 4 press 1 and rod diameter approx 22 mm 0 87 in 2 Input shaft bearing retainer and oil seal 1 Set bearing retainer 2 on vise 3 securely NOTE Use aluminum plates
85. cial tool A 09924 74510 B 09926 68310 C 09913 75510 1 Differential carrier Differential case FOR 2 DIFFERENTIAL PINION TYPE 1 After applying differential oil to side gear 4 pinions 5 pin ion shaft thrust washer 2 and spring washer 1 install them in differential right case 3 For correct installing direction of thrust washer 2 and spring washer 1 refer to the figure DIFFERENTIAL REAR 7F 7 2 Check pinion gear 1 for smooth rotation 2 Differential right case 3 Align pinion shaft hole position with differential case and drive in 3 spring pins 1 till they are flush with end surface of case Special tool A 09922 85811 4 In the same manner as described in Step 1 install thrust washer 2 spring washer 1 and side gear 4 3 Differential left case 5 Put bevel gear on differential case 1 and fasten them with bolts 2 by tightening them to specified torque Use thread lock cement for bolts 2 CAUTION Use of any other bolts than that specified is prohibited A Cement 99000 32020 Tightening torque Bevel gear bolt a 85 N m 8 5 kg m 61 5 Ib ft 7F 8 DIFFERENTIAL REAR 6 Install special tool to differential case assembly and check that preload is within specification below If preload exceeds specified value check if foreign matter is caught or gear is damaged Special tool B 09928 06010 002 Side gear preload Max 2 5 N m 0 25 kg
86. ck for proper engage ment smooth rotation with counter shaft NOTE For vehicle equipped with scissors gears align paint match marks 1 marked before disassembly as shown in figure when installing main shaft to lower case 6 2 After cleaning mating surfaces of both cases coat mating surface of upper case 8 with sealant evenly and put it over lower case 6 At this time all gears and forks should be set to neutral position A Sealant 99000 31150 Wik MU Mi 2 Scissors low gear if equipped 3 Main shaft low gear i Hiii ay a Q X wa h w K h 4 Scissors reverse gear if equipped 5 Main shaft reverse gear 3 Place bolts at their positions and check to make sure that their height from case surface is the same before tightening them Also check clamp position and torque them to specifi cation Tightening torque Upper case bolt a 23 N m 2 3 kg m 17 0 Ib ft A Bolt height before screw in 4 Apply sealant A to mating surface of input shaft bearing retainer 1 and its bolts 2 then install them A Sealant 99000 31110 Tightening torque Input shaft retainer bolt a 23 N m 2 3 kg m 17 0 Ib ft 5 Install clutch housing 1 and torque its bolts 2 to specifica tion Tightening torque Clutch housing bolt a 50 N m 5 0 kg m 36 5 Ib ft MANUAL TRANSMISSION TYPE 1 7A 31 6 Install release bearing 7 Clean m
87. damage to case when removing retaining ring e Confirm direction of bearing and bearing race for reas sembly 30 Remove reverse brake retainer 1 Special tool A 09941 84510 B 09926 98320 2 Nut M12 X 1 75 31 Remove brake applying cover 1 32 Remove rear action sleeve and reverse brake piston by blow ing air into hole 1 with hole 2 closed 33 Undo caulking of sleeve cover 1 by using moderate stick 2 and move sleeve cover 7B1 10 AUTOMATIC TRANSMISSION 4 A T 34 Using a punch drive out manual shift lever pin pull out man ual shift shaft 2 and remove manual shift lever 1 Then remove sleeve cover from manual shift lever 1 35 Remove oil seal 1 from both sides of transmission case Sub Assembly Repair Oil pump 2 Oil pump body oil seal 6 Oil pump cover 8 Oil pump body AUTOMATIC TRANSMISSION 4 A T 7B1 11 DISASSEMBLY 1 Remove 6 bolts oil pump cover 1 drive gear and driven gear in that order 2 Remove oil pump cover O ring INSPECTION e Check seal ring 2 and bushing 1 for wear and damage e Check clearance between outer gear 1 and body Clearance between outer gear and body Standard 0 07 0 15 mm 0 0028 0 0059 in Service limit 0 30 mm 0 0118 in e Check tip clearance between inner gear 1 and outer gear Tip clearance between inner gear and outer gear Standard 0 11 0 14 mm 0 0044 0 0055 in Service limit 0 30 mm
88. direction 2 Insert interlock cam component 1 to rear case 2 3 Set interlock cam component 1 as shown in figure and drive interlock cam pin 2 using special tool Special tool A 09922 85811 4 Install new interlock cam plug 1 and tighten it to specifica tion Tightening torque Interlock cam plug a 18 5 N m 1 85 kg m 13 5 Ib ft MANUAL TRANSMISSION TYPE 3 7A2 35 5 Install new oil seal to rear case so that end surface of oil seal becomes flush with that case Apply grease to oil seal lip Grease 99000 25010 Special tool B 09913 77510 6 Install counter shaft gutter 2 to transmission rear case 1 Transmission intermediate case and front case loca tion of knock and plug e Install Knock pin 1 and plug 2 Sealant applied to front case as shown A Sealant 99000 31110 Plug installing position a 2 0 mm 0 079 in 7A2 36 MANUAL TRANSMISSION TYPE 3 e Install knock 1 into front case 2 as shown in figure A Front side B Rear side Transmission Unit NOTE e Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear e Use new circlips on shaft for installation Don t reuse circlips 1 Set intermediate case 1 to vise 3 Clean mating surfaces of intermediate case both sides if intermediate case Is reused 2 Aluminum plate 2 Install main shaft assembly 1 to intermediate c
89. e 2 Special tool H 09900 06108 29 Using plastic hammer drive input gear 2 out of front case 1 NOTE e Be careful not to damage oil seal 3 by hitting e If removed do not reuse oil seal 3 TRANSFER 4WD 7D 9 30 Remove circlip 2 of input gear 1 by using special tool Special tool 1 09900 06107 31 Remove bearing 2 from input gear 1 by using puller 3 and press NOTE Use metal pad for this removal or gear spline may get damaged Special tool J 09951 76010 32 With spring 8 on front drive fork shaft 4 Compressed remove circlip 1 and then remove fork 2 and spring 3 33 Remove center case gutter 1 from center case 2 with wrench 7D 10 TRANSFER 4WD Component Inspection e Check each ball bearing for smooth rotation If found abnormal replace e Check each spring for distortion or breakage and change it with new one as necessary Especially for locating springs 1 measure each free length a and replace if it is below service limit Locating spring free length a Standard 19 5 mm 0 768 in Service limit 18 0 mm 0 709 in e Check needle bearing and bearing contacting surface for damage Replace as required e Check gear tooth surface and shift mechanism in the same manner as with transmission Correct or replace as necessary e Check drive chain and sprockets for abnormal wear or dam age Replace as required e Check oil seal f
90. e Do not compress spring more than necessary and do not allow it fall or tilt AUTOMATIC TRANSMISSION 4 A T 7B1 53 3 Prepare a stand as shown in the figure It is necessary because work will be done with transmission case set upright from this step on 15 7 in am NOTE 35 mm 1 4 in e To protect transmission case against damage spread cloth on stand where case contacts 13 8 in e A stand of such size as shown in figure will facilitate work 4 Install thrust output shaft bearing and thrust bearing output shaft race after lubricating them with grease NOTE Make sure that thrust bearing output shaft race is installed in proper direction 5 Install brake applying tube 1 so that its lug fits in a groove in transmission case After installation check that 4 lugs 3 along the underside of brake applying tube fit inside of reverse brake piston and leaf spring 2 is installed properly 6 Remove reverse brake reaction plate of planetary gear assembly and align lugs of reverse brake plate reverse brake disc and reverse brake packing plate Install planetary gear assembly to transmission case so that aligned lugs fit in groove in transmission case 7B1 54 AUTOMATIC TRANSMISSION 4 A T 7 Measure clearance between reverse brake plate and lugs of transmission case If measured value is less than standard range it is possible that something is installed improperly or dust or fluid is on reverse brake disc etc I
91. e at the extreme right And then remove O rings from pistons INSPECTION Direct Clutch Piston Return Spring e Measure free length Standard free length of direct clutch piston return spring 15 13 mm 0 595 in er 8 p N s aS l Direct Clutch Piston e Shake piston to check that ball is not stuck e Apply air pressure and check that there is no leakage ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points e Always use new O ring and apply A T fluid before installa tion e Do not align opening in retaining ring 2 with lug of direct clutch piston return spring at retainer Special tool A 09926 98310 AUTOMATIC TRANSMISSION 4 A T 7B1 27 e Use care so that direct clutch piston return spring will not fall or tilt CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform e Do not match opening 1 in retaining back plate ring with cutout 2 in direct clutch cylinder e Install clutch backing plate with its grooved side facing the front 7B1 28 AUTOMATIC TRANSMISSION 4 A T Center support 3 B1 brake Second coast brake 8 Clutch backing plate 13 B2 brake disc piston 14 Planetary sun gear 15 B2 brake hub assembly AUTOMATIC TRANSMISSION 4 A T 7B1 29 DISASSEMBLY 1 Remove retaining ring Special tool A 09920 76010
92. e body bolt nominal length a 25 mm 0 98 in b 30 mm 1 18 in c 47 mm 1 85 in d 60 mm 2 36 in 37 Install new gaskets oil screen spacer and oil screen Tightening torque Oil screen bolt 5 5 N m 0 55 kg m 4 0 Ib ft 38 Lubricate new O ring with A T fluid and attach it to grommet of solenoid wire harness Then connect solenoid wire har ness to transmission case and fix it with solenoid wire har ness clamp Connect each connector to solenoid And install new gasket and brake applying cover Tightening torque Brake applying cover bolt 10 N m 1 0 kg m 7 5 Ib ft 7B1 62 AUTOMATIC TRANSMISSION 4 A T 39 Using a plastic hammer connect forward clutch applying tube 1 lubricant applying tube 2 reverse brake applying tube 3 and brake applying tube 4 in such order as shown in figure 40 Install 2 oil pan magnets to transmission oil pan in such way that they do not interfere with oil tubes and install transmis sion oil pan with new oil pan gasket NOTE Align cutout in oil pan gasket with that in transmission case Tightening torque Transmission oil pan bolt 4 5 N m 0 45 kg m 3 3 Ib ft 2 Oil pan gasket 41 With wood rough key attached to output shaft install sensor rotor by aligning its key groove with wood rough key and install C ring by using special tool Special tool A 09920 76010 1 Retaining ring 42 For G16 engine model install adapter case 1 with
93. e limit ME EE ees Locating spring free length b B Standard 27 0 mm 1 063 in WNA i Service limit 24 0 mm 0 945 in Rear Case e If oil seal 1 leaks and or its lip is excessively hardened replace it with new one and at the same time check main shaft where oil seal contacts If contacting surface is not smooth correct or replace Apply grease to oil seal lip por tion Grease A 99000 25010 Special tool A 09913 75510 2 Rear case 7A 18 MANUAL TRANSMISSION TYPE 1 e f oil leakage exists at counter shaft end plug 2 replace it Special tool B 09913 75520 1 Rear case Unit Assembly Gear Shift Lever Case 4WD Model 1 Wash and inspect each part and replace if necessary Also check items as described below and correct whatever neces sary carefully by using reamer oilstone and the like wash it thoroughly and reassemble them Items to be checked are e Shift shaft should go into case smoothly e Shift lever limit yoke and shift arm should go into shift shaft smoothly 2 Insert shift shaft 1 as shown while making sure that inner parts are in proper direction NOTE e Cut off portion 5 in shift shaft should face downward when shift shaft 1 is installed e Use care for installing direction of shift limit spring 4 e Shift arm should be installed at the same time 2 Shift lever 3 Shift limit yoke 3 Drive in spring pin single short for reve
94. ear Standard 44 015 44 040 mm 1 7329 1 7339 in e Check chamfered part of each sleeve for damage and exces sive wear and replace as necessary e Check each synchronizer key and synchronizer spring and replace as necessary e Check splined portions and replace parts if excessive wear is found e Check 2nd gear 1 thrust clearance by using thickness gauge 2 If clearance is out of specification repress fit or replace defective part 2nd gear thrust clearance Standard 0 10 0 25 mm 0 004 0 009 in e Check low gear 1 thrust clearance by using thickness gauge 2 If clearance is out of specification repress fit or replace mainshaft bearing and 5th gear Low gear thrust clearance Standard 0 15 0 45 mm 0 006 0 018 in Counter shaft and reverse idle gear e Using micrometer check diameter of counter shaft as shown in the figure If measured valve is out of specification replace it Counter shaft diameter standard a 29 984 30 000 mm 1 1805 1 1811 in b 34 000 34 015 mm 1 3386 1 3392 in 7A2 24 MANUAL TRANSMISSION TYPE 3 e Measure width a of 5th gear shift fork and groove width b of 5th gear synchronizer sleeve and then calculate clear ance c as follows Clearance o b are i If clearance exceeds limit replace fork and sleeve Clearance c between fork and sleeve Standard 0 26 0 84 mm
95. ed with groove on flange periphery e This installation requires no spacer or oil seal e Before taking measurement with spring balance 2 or torque wrench 3 check for rotation by hand and apply small amount of oil to bearings Special tool A 09922 75222 B 09926 78311 Pinion bearing preload a 9 0 17 0 kg cm 7 8 14 7 Ib in Spring measure reading 1 8 3 4 kg 4 0 7 5 Ib 4 Socket with adapter 2 Set dial gauge to bevel pinion mounting dummy and make 0 zero adjustment on surface plate NOTE e When setting dial gauge to mounting dummy tighten screw lightly Be careful not to overtighten it which will cause damage to dial gauge e With dial gauge set turn dummy back and force by hand a couple of times and attain accurate 0 zero adjustment e It is desirable that short pointer indicates beyond 2 mm when long one is at 0 zero Special tool C 09926 78311 D 09900 20606 1 Surface plate 2 Screw 7E 12 DIFFERENTIAL FRONT 3 Place zero adjusted mounting dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip NOTE e Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accu rately e When dial gauge measuring tip extends from 0 Zero position pointer turns counterclockwise e Measured value may exceed 1 mm Therefore it is also necessary to know read
96. eedle bearing and counter shaft 5th gear 33 Remove thrust washer 2 and ball 1 34 Remove reverse link stay 1 from intermediate case 35 Remove reverse idle gear 1 and shaft 2 Ni i lt a 36 Remove main and counter shaft bearing plate 1 MANUAL TRANSMISSION TYPE 2 7A1 15 37 Remove C ring 1 of counter shaft rear bearing Special tool B 09900 06107 38 Using rod 2 and hammer remove counter shaft rear bear ing 1 and counter shaft 3 NOTE This removal requires 2 persons One should hold counter shaft 3 and the other should remove bearing 1 by using rod 2 and hammer 39 Remove input shaft assembly 1 with synchronizer ring from main shaft assembly 2 NOTE When removing input shaft be careful not to drop bear ing roller 40 Remove C ring of main shaft and pull out main shaft assem bly 1 NOTE If intermediate case is engaged with bearing firmly tap front face of intermediate case with plastic hammer lightly as it will cause main shaft assembly to come off forward 7A1 16 MANUAL TRANSMISSION TYPE 2 Sub Assembly Input shaft assembly Remove circlip of input shaft 1 and pull out bearing 2 with puller 3 and press CAUTION Sealed bearing must not be washed Replace it with new one when required Main shaft assembly 1 Remove circlip 1 from main shaft 2 as shown in the figure 2 Pull out 5th gear 1 needle bush 2 needle
97. eeds limit replace fork and sleeve Clearance c between fork and sleeve Standard 0 15 0 35 mm 0 006 0 014 in Limit 1 0 mm 0 039 in 7A2 22 MANUAL TRANSMISSION TYPE 3 e Measure groove a of low speed gear shift fork and flange width b of low speed synchronizer sleeve and then calcu late clearance c as follows Clearance o ta h If clearance exceeds limit replace fork and sleeve Clearance c between fork and sleeve Standard 0 15 0 41 mm 0 006 0 016 in Limit 1 0 mm 0 039 in e Check diameter of main shaft 1 and thickness of main shaft 1 flanges as shown in the figure If measured value is out of specification replace main shaft 1 Main shaft specification diameter and thickness 46 984 47 000 mm me00 180m 37 984 38 000 mm Term C 4 80 5 20 mm OO C OO een 38 979 38 995 mm 1 5346 1 5352 in e Using V blocks 1 and dial gauge 2 check runout If runout exceeds limit below replace main shaft 3 Main shaft runout limit 0 015 mm 0 0006 in MANUAL TRANSMISSION TYPE 3 7A2 23 e Using cylinder gauge 1 check inside diameter of each gear If its inside diameter exceeds specification replace it Inside diameter of gear 1st gear Standard 46 015 46 040 mm 1 8116 1 8126 in 2nd gear Standard 53 015 53 040 mm 2 0872 2 0882 in 3rd g
98. een vise 5 and intermedi 2 7 ate case 4 to protect intermediate case 4 against dam ory age 1 OD P A a I Q 11 Remove locating screws 1 locating springs 2 and locat ing ball 3 as shown in the figure 12 Remove low speed gear shift fork bolt 1 and high speed gear shift fork bolt 2 7A2 10 MANUAL TRANSMISSION TYPE 3 13 Remove circlips 1 from high speed gear shift shaft 2 and low gear shift shaft 3 using flat head screw drivers 4 or the like 14 Remove high speed gear shift shaft 2 and high speed gear shift fork 1 15 Remove interlock pin 1 and straight pin 2 using magnet 3 16 Remove low speed gear shift shaft 2 and low speed gear shift fork 1 17 Remove interlock pin 1 by using magnet 2 MANUAL TRANSMISSION TYPE 3 7A2 11 18 Remove circlips 1 from 5th gear shift shaft 2 and 5th amp reverse guide shaft 3 using flat head screw drivers 4 or the like 19 Drive spring pin 1 out from 5th gear shift fork 2 using spe cial tool Special tool A 09922 85811 20 Remove 5th gear shift shaft 1 and 5th gear shift fork 2 21 Remove interlock pin 1 from intermediate case 2 using magnet 3 22 Remove ball 4 from reverse shift fork 5 using magnet 3 SANS AI SH EB N z Z 7A2 12 MANUAL TRANSMISSION TYPE 3 23 Pull out 5th amp reverse guide shaft 1 from intermediate case 2 NOTE When pulling 5th amp r
99. em take out spring 4 steel ball 5 and pin 6 For transfer for TYPE 2 and TYPE 3 manual transmissions remove select return spring bolt 8 and then return spring 9 7 Reduction shift yoke 4 By hammering special tool drive spring pin out of reduction shift yoke NOTE e Pin may drop into case when driven out Therefore take it out when case is disassembled e After spring pin is removed yoke may be either taken out Special tool A 09922 85811 TRANSFER 4WD 7D 5 5 Remove 15 rear case bolts and then separate cneter case 1 and rear case 2 by using special tool NOTE To separate center case 1 and rear case 2 use special tool at 4 points in turn and make opening wider evenly Special tool B 09912 34510 1 Center case 2 Rear case 6 Remove circlip 1 from output rear shaft 2 by using screw drivers and hammer then pull out speedometer drive gear 3 and steel ball NOTE Watch out for steel ball which comes off from shaft when speedometer drive gear is pulled out so as not to lose it 7 Remove circlip for bearing and pull out output rear shaft No 2 bearing 1 by combination of special tools Special tool C 09921 57810 D 09927 18411 8 Remove synchronizer plate 1 screws 2 and pull out sprocket bush 4 and needle bearing 3 from output rear shaft 5 9 Remove drive sprocket 6 with drive chain 7 and synchro nizer plate 1 NOTE Watch out
100. er case 2 to transmission without using sealant for functional check 13 Install shift control lever and check to make sure that it shifts smoothly according to shift pattern NOTE e Apply thread lock cement C to control lever locating bolts 1 when replaced e Be sure to apply sealant to mating surface of gear shift lever for its final installation C Cement 99000 32020 Tightening torque Control lever locating bolt d 17 N m 1 7 kg m 12 5 Ib ft Gear Shift Lever Case 2WD Model 1 Wash and inspect each part and replace if necessary Also check items as described below and correct whatever neces sary carefully by using reamer oilstone and the like wash it thoroughly and reassemble them Items to be checked are e Shift shaft should go into case smoothly e Shift lever limit yoke and shift arm should go into shift shaft smoothly 2 Insert shift shaft 1 as shown while making sure that inner parts are in proper direction NOTE e Cut off portion 5 in shift shaft should face downward when shift shaft 1 is installed e Use care for installing direction of shift limit spring 4 e Shift arm should be installed at the same time 2 Shift lever 3 Shift limit yoke 3 Drive in spring pin single short for reverse gear shift limit yoke 4 Drive in spring pin double for shift lever 5 Drive in spring pin single long for return spring MANUAL TRANSMISSION TYPE 1 7A 21 6
101. ever Case 1 Remove case plate 2 With case supported with soft jawed vise remove lever locat ing bolts 6 NOTE Use aluminum plates between vise and case to protect case against damage 3 Using special tool drive spring pin 2 into gear shift arm 5 as far as the position shown in the figure CAUTION When driving spring pin 2 use care not to damage gear shift lever case 1 Special tool A 09922 85811 4 Likewise drive spring pin 2 into gear shift lever 3 as far as the position shown in the figure CAUTION When driving spring pin 2 use care not to damage gear shift lever case 1 Special tool A 09922 85811 5 Remove case plug 7 6 Pull out gear shift shaft 4 from gear shift lever case 1 and take out gear shift lever 3 Transmission Unit 1 Remove clutch release bearing 1 release fork 2 and clutch housing 3 7A1 8 MANUAL TRANSMISSION TYPE 2 2 Remove back up light switch 1 3 Remove locating screw 1 locating spring 2 and locating ball 3 as shown in the figure 4 Remove return spring low bolt 1 and return spring reverse bolt 2 5 Remove gear shift shaft inner bolt 1 plug 2 MANUAL TRANSMISSION TYPE 2 7A1 9 6 Using bolt hole pull gear shift inner shaft 2 and then remove gear shift shaft inner lever 1 7 After removing transmission case bolts nut remove trans mission rear case 1 from intermediate case 2
102. everse guide shaft 1 place hand so as to catch ball 3 jumping out of reverse gear shift fork 4 24 Remove compression spring 5 from reverse gear shift fork 4 using magnet 25 Remove reverse gear shift fork 4 with reverse gear shift arm 6 from reverse gear shift arm bracket 7 26 Remove circlip 1 and then remove reverse gear shift arm 2 from reverse gear shift fork 3 27 Remove reverse gear shift arm bracket 1 from intermediate case 2 28 Remove circlip 1 from counter shaft 2 using flat head screw drivers 3 or the like MANUAL TRANSMISSION TYPE 3 7A2 13 29 Remove 5th speed synchronizer dog 1 using special tools and adjustable angle wrench 2 Special tool A 09944 36011 B 09913 85230 30 Remove 5th amp reverse synchronizer ring 31 Pull off 5th amp reverse synchronizer sleeve 1 counter shaft 5th gear assembly 2 and needle bearing 3 together from counter shaft 4 32 Remove synchronizer key spring 1 and balk levers 2 from counter shaft 5th gear 3 33 Remove 5th amp reverse synchronizer sleeve 4 from counter shaft 5th gear 3 34 Remove circlip 1 using special tool and then remove plate spring 2 Special tool A 09900 06107 7A2 14 MANUAL TRANSMISSION TYPE 3 35 Remove thrust washer 2 and pin 1 36 Remove main and counter shaft bearing retainer 1 37 Remove reverse idle gear 1 and shaft 2 NS IRSA S
103. f it exceeds standard range for G16 and J20 engine models replace reverse brake disc reverse brake plate or reverse brake backing plate If it exceeds standard range for H25 engine model adjust it to standard clearance with selective reverse brake backing plates as shown after making sure reverse brake disc reverse brake plate and reverse brake backing plate are in good condition If they are not in good condition replace Standard clearance between reverse brake plate and lugs of transmission case 0 56 2 29 mm 0 022 0 090 in G16 engine 0 61 2 64 mm 0 024 0 103 in J20 and H25 engines Available plate thick 3 25 3 50 3 75 4 00 4 25 mm ness for H25 engine 0 128 0 138 0 148 0 157 0 167 in model only 8 Install reverse brake reaction plate so that its lug with dent comes to the same position as leaf spring 1 Relief spring Z 7 9 Using screwdriver with vinyl tape or the like wound at its tip install retaining reaction plate ring 1 After installation check that ring is in groove securely AUTOMATIC TRANSMISSION 4 A T 7B1 55 10 After confirming that lugs of all brake plates and brake discs are in grooves securely hold retaining direct clutch ring 1 of planetary sun gear install center support assembly by align ing fluid holes 2 in center support and transmission case NOTE Unless retaining direct clutch ring of planetary sun gear is held brake valve
104. from damage e Work gloves or shop cloth should not be used Use a nylon cloth or a paper towel e When separating the case joint do not pry with a screwdriver or such but tap with a plastic hammer lightly e Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during disas sembly and reassembly e Wash the disassembled parts in ATF Automatic Transmission Fluid or kerosene using care not to allow ATF or kerosene to get on your face etc and confirm that each fluid passage is not clogged by blowing air into it But use ATF to wash the disc resin washers and rubber parts e Replace each gasket oil seal and O ring with a new one e Apply ATF to sliding or rotating parts before reassembly e A new disc should be soaked in ATF at least 2 hours before use Part Inspection and Correction Table Part inspector Correction Casted part machined part Clogged fluid passage Flaw on installing surface residual Remove with oil stone or replace gasket part Bearing Unsmooth rotation Bushing thrust washer Flaw burr wear burning Oi seal gasket Worn seal ring on its periphery or Replace side Piston seal ring oil seal gasket etc Gear o OM fre Snap ring Thread OE OO O O Clutch disc brake disc Wear burning distortion damaged Replace D e Clutch plate brake plate Wear burning distortion damaged Replace D ieee Sealing surface where Flaw rough surface
105. ft 5 Install oil seal to rear case so that end surface of oil seal becomes flush with that case Apply grease to oil seal lip Grease 99000 25010 Special tool B 09913 77510 6 Install counter shaft gutter 2 to transmission rear case 1 MANUAL TRANSMISSION TYPE 2 7A1 33 Transmission intermediate case and front case loca tion of knock and plug e Install Knock pin 1 and plug 2 Sealant applied to front Section case as shown A A A Sealant 99000 31110 Approx 40 2mm I 0 079 in e Install knock pin 2 ring pin 1 as shown in the figure A Front side B Rear side Transmission Unit NOTE e Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear e Use new circlips on shaft for installation Don t reuse circlips 1 Set intermediate case 1 to vise 8 Clean mating surfaces of intermediate case both sides if intermediate case Is reused 2 Aluminum plate 7A1 34 MANUAL TRANSMISSION TYPE 2 2 Install main shaft assembly 1 to intermediate case NOTE When fitting of intermediate case 1 and bearing is tight tap rear face of intermediate case 1 with plastic hammer lightly as it will cause main shaft assembly 2 to install 3 Fix with C ring 1 by using special tool Special tool A 09900 06107 4 Align key slots of synchronizer ring and synchronizer keys and set input shaft assembly to mai
106. ft b Fix reduction shift yoke with spring pin 4 while aligning shift yoke with shift shaft as shown in the figure 3 Screwdriver 42 For transfer for A T and TYPE 1 manual transmission per form the following procedure a With reduction shift shaft 1 shifted to left at high speed side as shown in the figure fit yoke 2 to shaft 1 and fix it with spring pin NOTE Be careful not to let spring pin fall off b Torque locating spring bolts 4 of shifters to specification Tightening torque Locating spring bolt g 26 N m 2 6 kg m 19 0 Ib ft 3 Front drive shift shaft 7D 22 TRANSFER 4WD 43 Install steel balls 1 and 4WD 2 4WD LOW switches Tightening torque 4WD switch h 20 N m 2 0 kg m 14 5 Ib ft 4WD Low switch 20 N m 2 0 kg m 14 5 Ib ft 44 Install vehicle speed sensor to rear case 45 Fix lead of 4WD switch 1 with clamp 46 Apply grease A to select return system parts and install them Then torque select return spring bolt 5 to specifica tion For transfer with A T or TYPE 1 manual transmission only A Grease 99000 25010 Tightening torque Select return spring bolt A T or TYPE 1 M T i 35 N m 3 5 kg m 25 5 Ib ft 47 Clean mating surfaces of both gear shift lever case 7 and rear case and with sealant C applied to mating surface of gear shift lever case push both cases together C Sealant 99000 31110 48 Tighten gear shift lever
107. g Torque Specification Fastening part Tightening torque Nm et Transfer oi filerlevel anddranpugs 1 2 17 0 Transmission ol fillerlevet and drain pugs s 275 Bakpia PT 325 Shiftlever case plate screws 6 45 Gear siftevercase bots 128 2 145 3 17 19 Locating spring screws E 14 0 Input shaft bearing retainer bolt 12 5 7 Transmission case pots ooo f 255 285 inner gear shit shaft pug tt 1 449 Retur spring lowreversebois 28 28 205 Clutch housing bolis Transmission to transferbois 80 50 35 Required Service Material Recommended SUZUKI product FJ Namba Lithium grease SUZUKI SUPER GREASE A Oil seal lips 99000 25010 Select return system Input shaft bearing roller Locating rollers Thread lock cement THREAD LOCK CEMENT Shift control lever locating screws SUPER 1333B Gear shift fork bolts 99000 32020 Input shaft retainer bolts Sealant SUZUKI BOND No 1215 Oil drain and filler level plugs 99000 31110 Mating surface of gear shift lever case Mating surface of transmission cases Front case plugs Gear shift shaft plug 7A1 46 MANUAL TRANSMISSION TYPE 2 09912 34510 Case separator 09913 75821 Installer attachment 09927 08220 Shaft remover 09925 18011 Installer attachment Special Tool 09913 75510 09940 51710 Bearing installer Bearing installer O D 70 5 mm 09924 84510 004 09925 78210 6 mm Bearing installer adapter Spring pin remover 09940 53111 09900 0610
108. ge e Check bearings for wear or discoloration e Check differential carrier for cracks e Check drive bevel pinion and bevel gear for wear or cracks e Check side gears pinion gears and pinion shaft for wear or damage e Check side gear spline for wear or damage Differential left case e Check clutch for smooth movement by pushing plate of axle lock clutch fitted to differential left case Also check return spring 1 for settling e Check teeth of axle lock clutch 2 fitted to differential right case for wear damage and any other faulty condition 1 Left case DIFFERENTIAL FRONT 7E 7 Free axle hub Check teeth of free axle hub 1 for wear damage and any other faulty condition 2 Differential pinion Actuator 1 Connect special tool air compressor actuator 1 and hoses as shown in the figure NOTE Loosen adjusting screw of special tool before connecting hoses to special tool Special tool A 09918 18110 2 With pressure from compressor applied to special too adjust pressure to specified level by turning adjusting screw of spe cial tool and check actuator for operation Also check that there is no air leakage from actuator Specified pressure for actuator inspection 38 0 kPa 0 38 kg cm 5 40 psi Actuator stroke 3 mm 0 118 in A When pressure applied 7E 8 DIFFERENTIAL FRONT Subassembly Adjustment and Reassembly Judging from faulty conditions noted before dis
109. h with case surface Apply grease A to oil seal lip A Grease 99000 25010 Special tool B 09913 75520 TRANSFER 4WD 7D 13 6 Install rear case plate 1 and bolt 2 applying thread lock cement B NOTE Removal of rear case plate is not required normally How ever if it is removed or replaced install it with bolt applied with thread lock cement B Cement 99000 32020 Tightening torque Rear case plate bolt a 8 N m 0 8 kg m 5 5 Ib ft 7 Using press and special tools install bearings 2 to front shaft 1 Bearings for both front and rear are identical Special tool C 09913 84510 8 Using press drive output front shaft assembly 2 into center case 1 9 Using press and special tools install output rear shaft No 1 bearing 1 into output rear shaft 2 Place circlip portion of bearing on top as shown in figure Special tool D 09925 18011 E 09940 53111 7D 14 TRANSFER 4WD 10 Install needle bearing 3 and output low gear 4 and then press fit reduction clutch hub 5 onto output rear shaft 1 by using press and special tool and secure them with circlip 6 Hub has specific installing direction Special tool D 09925 18011 E 09940 53111 2 Output rear shaft No 1 bearing 7 Puller 11 Combine special tools and press fit output rear shaft assem bly into center case 1 NOTE Use special tool F with its under cut side faced down
110. haft 11 Second brake 2 Overdrive input shaft 7 Forward clutch 12 Reverse brake 3 Oil pump 8 Direct clutch 13 Front planetary gear 4 Overdrive brake 9 One way clutch 14 Rear planetary gear 5 Overdrive clutch 10 Second coast brake 15 Overdrive planetary gear AUTOMATIC TRANSMISSION 4 A T 7B1 3 Torque Converter Diagnosis Stator Assembly Freewheels If the stator roller clutch becomes ineffective the stator assembly freewheels at all times in both directions With this condition the vehicle tends to have poor acceleration from a standstill If poor acceleration problems are noted what to be checked first are that the exhaust system is not blocked the engine is running properly and the transmission is in 1st gear when starting out Stator Assembly Remains Locked Up If the stator assembly remains locked up at all times the engine rpm and vehicle speed will tend to be limited or restricted at high speeds The vehicle performance when accelerating from a standstill will be normal Engine overheating may be noted Visual examination of the converter may reveal a blue color from the overheating that will result Under above conditions if the converter has been removed from the transmission the starer roller clutch can be checked by insert ing a finger into the splined inner race of the roller clutch and try ing to turn the race in both directions The inner race should turn freely clockwise but be heavy to turn countercl
111. ication Dmak Cirelip thickness A 280 285 mm 0 1103 0 1122 in B 285 290mm 0 1122 0 1141 in pp ee Fr ee 2 Thickness gauge 15 Fix with circlip 1 as shown in figure and check that counter shaft 5th gear turns lightly MANUAL TRANSMISSION TYPE 3 7A2 41 16 Check counter shaft 5th gear 1 thrust clearance using thickness gauge 2 If clearance exceeds limit repeat Step 1 to 15 again or replace defective part s Counter shaft 5th gear thrust clearance Standard 0 10 0 35 mm 0 0040 0 0138 in 17 Install reverse gear shift arm bracket 1 to intermediate case Tightening torque Reverse gear shift arm bracket bolt a 18 N m 1 8 kg m 13 0 Ib ft 18 Install reverse gear shift arm 1 to reverse gear shift fork 2 fixing it with new circlip 3 19 Fit reverse gear shift arm fork 1 to reverse idle gear and then install reverse gear shift arm fork 1 to reverse gear shift arm bracket 2 20 Insert spring 3 and ball 4 to reverse gear shift fork 5 using magnet 21 Insert 5th amp reverse guide shaft 1 to reverse gear shift fork 3 and intermediate case 4 from front side pushing ball 5 by rod 2 7A2 42 MANUAL TRANSMISSION TYPE 3 22 Insert ball 1 to reverse gear shift fork 2 and interlock pin 3 to intermediate case 4 using magnet N yy BESS WT IN 23 Install 5th gear shaft 2 after fitting 5th gear shift fork 1 to 5th amp reve
112. ide bearings should be between 2 8 and 3 2 kg 6 17 and 7 05 Ib Special tool D 09922 75222 3 Universal joint flange 4 Socket with adapter NOTE e Bearing preload can be checked roughly by using flange holder as shown in left figure In this measure ment holder arm itself will work as balance weight and torque will be replaced with angle However flange should be rotated very slowly with hand support so as not to allow over revolution due to inertia Repeat side bearing adjustment until gear backlash and composite bearing preload are compatible within specification if failed to obtain specified measure ments first Special tool E 09922 66020 A Pinion bearing starting torque range B Pinion bearing plus side bearing starting torque range 7F 16 DIFFERENTIAL REAR kg em lb in kg 20 0 17 3 Drive bevel pinion bearing starting torque preload side bearing starting torque preload 33 6 Degree Degree 7 5 Ib 1 8 1 9 20212223 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 23 3 3 4 kg 7 9 11 3 14 7 Ib in EE NDD RENEE ET EEE EAT ee 9 0 13 0 17 0 kg cm Drive bevel pinion bearing starting torque preload 8 Torque bearing cap bolts 2 to specification and install bear ing lock plates Tightening torque Lock plate bolt b 12 N m 1 2 kg m 9 0 Ib ft Bearing cap bolt c 85 N m 8 5 kg m 61 5 Ib ft 1 Lock plate bolt 9 As final step check gear tooth contact as fol
113. ing of short pointer Special tool C 09926 78311 D 09900 20606 4 Obtain adjusting shim thickness by using measured value by dial gauge which represents c in the first figure of Drive Bevel Pinion in this section in the following equation Measurement printed on Necessary Dial gauge shim thick 94 measured value oc ness f pinion e 94 in above equation is a b of mounting dummy special tool as shown in the first figure of Drive Bevel Pinion in this section 5 Select adjusting shim s 2 closest to calculated value from among the following available sizes and put it in place and then press fit front bearing 1 Special tool E 09925 18011 F 09927 66010 Available shim thickness 1 12 1 15 1 18 1 21 1 24 1 27 1 30 and 0 3 mm 0 044 0 045 0 046 0 047 0 048 0 049 0 050 and 0 012 in 3 Bevel pinion A Closest value to f calculated 6 With new pinion spacer 3 inserted as shown in the figure install rear bearing 5 to differential carrier 4 NOTE e Make sure to use new spacer for reinstallation e Apply oil to bearings 1 Bevel pinion 2 Front bearing DIFFERENTIAL FRONT 7E 13 7 Using special tool and plastic hammer drive oil seal 2 into differential carrier 1 till it becomes flush with carrier end Then apply grease A to oil seal lip Special tool G 09951 18210 A Grease 9900
114. ining ring 7 Return spring 11 Direct clutch cylinder 4 Clutch backing plate 8 O ring AUTOMATIC TRANSMISSION 4 A T 7B1 25 DISASSEMBLY 1 Install direct clutch assembly 1 to center support 2 and with 4 8 kg cm air pressure applied to second fluid hole from the left measure stroke of direct clutch piston as shown in figure If it is not within standard range use 3 55 mm 3 75 mm or 4 0 mm 0 140 in 0 147 in or 0 157 in clutch backing plate to adjust it to standard stroke Standard direct clutch piston stroke 1 06 2 14 mm 0 042 0 084 in G16 and J20 engines 0 91 1 99 mm 0 036 0 078 in H25 engine 2 Remove direct clutch assembly from center support and then remove retaining ring 3 Remove clutch backing plate 1 and then remove clutch disc 3 and clutch plate 2 4 Using special tool and hydraulic press 1 compress direct clutch piston return spring 3 and remove retaining return spring ring 2 la Fas Special tool Ed 2 A 09926 98310 CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform 5 Remove direct clutch piston return spring 7B1 26 AUTOMATIC TRANSMISSION 4 A T 6 Install direct clutch cylinder to center support Remove direct clutch piston by blowing air into the second hole from the left as shown in the figure Also remove direct clutch inner piston by blowing air into hol
115. installing direction is as shown in figure 6 Hold bearing press fitted in step 7 with holder and press fit side bearing on the other side NOTE Be sure to use bearing holder for the purpose of protect ing lower bearing Special tool G 09944 66020 H 09951 16060 7E 10 DIFFERENTIAL FRONT Drive bevel pinion To engage bevel pinion and gear correctly it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described on the following Shown in the figure are relative positions of bevel pinion differential carrier and mounting dummy Special tool A 09900 20606 B 09926 78311 C 09922 75222 her Vicor hs He 3 C 1 Universal joint flange without groove P No 27110 60A00 a Pinion dummy height 2 No groove on flange periphery b Axle dummy radius 3 Nut a b Mounting dummy side 94 00 mm 3 70078 in 4 Rear bearing c Measured dimension d Differential carrier mounting distance a b c e e Bevel pinion mounting distance Marked in shaft in mm f Shim size for mounting distance adjustment d e 9 Bevel gear DIFFERENTIAL FRONT 7E 11 1 Install bevel pinion dummy with bearings into differential car rier and tighten flange nut 1 so that specified bearing pre load is obtained NOTE e This installation requires universal joint flange not equipp
116. ith depression side of keys 2 face center of hub 3 c Install springs 1 to internal circle of key locations with spring end gaps apart at angles about 120 degrees each FORWARD other in order to apply spring tension equally to each key NOTE TNR Before installing hub 3 sleeve 4 springs 1 and keys Sen 2 assembly to main shaft there is no specific installa tion direction on each component However when install ing assembly to main shaft gear side of sleeve 4 should face to forward direction as shown in the figure A Key location tooth B Flange C Depression of key 9 Install synchronizer ring 1 by matching its key slots to keys as shown in the figure FORWARD poe mm namnet _ rare St ere hats 10 Insert 2nd gear 2 needle bearing 3 and low speed sleeve hub assembly 4 with synchronizer ring to main shaft 1 AID KK IN M MANUAL TRANSMISSION TYPE 2 7A1 29 11 Press fit low speed sleeve hub assembly with special tool and press 1 Special tool A 09940 53111 12 Check 2nd gear thrust clearance referring to Main Shaft Assembly in this section 13 Apply grease to ball 1 and set it to main shaft 3 14 Install synchronizer ring 2 15 Install needle bearing 2 low gear 3 and needle bush 1 to main shaft NOTE e Check the cut in needle bush and ball are engaged e After installation check the
117. ith the clutch housing 7A 8 MANUAL TRANSMISSION TYPE 1 i IDT hd amp Eg S i 5 Remove 10 bolts and separate cases 1 2 by using special tool Special tool A 09912 34510 6 If equipped with scissors gears 3 5 put match mark 1 paint on teeth of low 4 and reverse 6 gear assembly as shown in the figure before taking out input and main shaft assembly from lower case 2 7 Take out input and main shaft assembly 8 Remove bearing circlip 2 at the rear part of counter shaft by using screwdriver 1 9 Remove bolt 3 for reverse idle gear shaft 2 and then remove idle gear 1 and shaft 2 as a set MANUAL TRANSMISSION TYPE 1 7A 9 10 Remove center bearing plate 1 by removing its 2 bolts 2 11 Remove outside circlip 1 of front bearing 2 on counter shaft 12 Using plastic hammer 2 drive counter shaft 1 rearward 13 Pull out 5th gear 2 and rear bearing 1 with bearing puller 3 and press NOTE e Apply pressing force while adjusting position of front bearing so that it will fit in its original position hole in lower case e Be sure to set flat face of puller 3 against 5th gear so as not to cause damage to teeth 14 In the same manner as 12 drive counter shaft rearward again 7A 10 MANUAL TRANSMISSION TYPE 1 15 Pull out reverse gear 1 with bearing puller 2 and press 16 Pull out roller bearing by hand and then remove shaft fr
118. its flange 2 to the front 7B1 16 AUTOMATIC TRANSMISSION 4 A T e Before installing piston inner O ring and piston outer O ring apply A T fluid to them e Install so that snap opening and projection 1 of clutch pis ton return spring will not match 2 Slot e Install retaining clutch ring and retaining brake hub so that their slots 2 will not match with dent 1 in O D clutch cylin der e For installing cushion clutch plate 1 refer to the figure 2 3 2 Clutch cylinder side l 3 Brake hub side AUTOMATIC TRANSMISSION 4 A T 7B1 17 Overdrive Case side AT 616 and J20 engines BI 25 engine 7B1 18 AUTOMATIC TRANSMISSION 4 A T DISASSEMBLY 1 Measure clearance between retaining ring 1 and brake backing plate 2 with thickness gauge If it is not within standard range replace brake disc or brake plate Clearance between retaining ring and brake backing plate Standard 0 56 1 38 mm 0 022 0 054 in G16 and J20 engines 0 40 1 38 mm 0 016 0 054 in H25 engine B AAE PT VG 2 Remove retaining ring 1 brake backing plate 2 brake disc 3 brake plate 4 cushion brake plate 5 in that order Then remove planetary ring gear thrust bearing race and thrust rear bearing 3 Remove retaining ring 1 retainer 2 and piston return spring 3 4 Blow air into fluid hole in O D case 2 and remove brake pis ton 1 5 Remove brake piston inner ring and brake
119. l synchronizer ring 1 by matching its key slots to keys as shown in the figure gt FORWARD MANUAL TRANSMISSION TYPE 2 7A1 27 3 Insert 3rd gear 2 needle bearing 3 and high speed sleeve hub assembly 4 with synchronizer ring to main shaft 1 4 Press fit high speed sleeve hub assembly 1 with special tool and press 2 Special tool A 09940 53111 5 Select circlip 1 that will make thrust clearance of clutch hub 0 1 mm 0 0039 in or less and install it Circlip thickness specification Circlip thickness C 1 1 75 1 80 mm 0 0689 0 0708 in D 1 1 80 1 85 mm 0 0709 0 0728 in D 1 1 85 1 90 mm 0 0729 0 0748 in E 1 90 1 95 mm 0 0749 0 0767 in E 1 195 2 00 mm 0 0768 0 0787 in F 200 2 05 mm 0 0788 0 0807 in F 1 205 210 mm 0 0808 0 0826 in Special tool B 09900 06107 6 After installing circlip check that 3rd gear turns lightly 7 Check 3rd gear 2 thrust clearance by using thickness gauge 1 If clearance is out of specification repress fit or replace 3rd gear thrust clearance Standard 0 10 0 25 mm 0 004 0 009 in 7A1 28 MANUAL TRANSMISSION TYPE 2 8 Assemble low speed synchronizer hub 3 sleeve 4 springs 1 and keys 2 according to the following proce dure a Slide hub 3 in sleeve 4 with aligning hub slots with key location teeth of sleeve 4 b Insert keys 2 in hub slots w
120. lation seat Standard dimension between end surface of case housing and drive plate installation seat a For G16 engine 21 5 mm 0 85 in For J20 engine 17 3 mm 0 68 in For H25 engine 17 4 mm 0 69 in 48 Check that torque converter turns smoothly and apply grease to center piece 1 of torque converter AUTOMATIC TRANSMISSION 4 A T 7B1 65 Bearing and Race Installation Diagram 7B1 66 AUTOMATIC TRANSMISSION 4 A T Tightening Torque Specification Fastening part Tightening torque Oil pump bolis Detent spring bolt Throttle cam bolt Pressure relief valve bolts 4 Rear upper valve body plate bolts 0 ee 40 Solenoid valve No 1 Shift solenoid valve bolts ps em Solenoid valve No 2 TCC solenoid valve bolts Pressure Pressure relief valve bolt valve bolt ee ae valve Lower valve body plate bolts sid plate bolts ae TCC Lock up control valve plates bolts sd control valve plates bolts Tes cone reuse M O T B G Parking lok pa rasket crew Oi pump assembly bots 1 2 22 wo Adapter case bolts g 6 engine 3 1 35 255 Adapter case bolts J20 and H2s engines 4 42 30 Manual shit shasoinat 404 30 Tarsmissin range swichockbok M ss os 40 ilpipe rens 1 o 30 20 Required Service Material Recommended SUZUKI product JE ir o OOOO U e Parts lubrication when installing Lithium grease SUZUKI SUPER GREASE C e Retaining parts in place when assembling
121. learance is out of specification repress fit or replace mainshaft bearing and 5th gear Low gear thrust clearance Standard 0 10 0 25 mm 0 004 0 009 in 7A1 22 MANUAL TRANSMISSION TYPE 2 Counter shaft and reverse idle gear e Using micrometer check diameter of counter shaft as shown in the figure If measured valve is out of specification replace it Counter shaft diameter standard a 25 986 26 00 mm 1 0231 1 0236 in b 30 957 30 972 mm 1 2188 1 2193 in e Check clearance between fork and sleeve If clearance exceeds limit replace fork and sleeve Clearance between fork and sleeve Standard 0 15 0 35 mm 0 006 0 013 in Limit 1 0 mm 0 039 in e Check clearance a between synchronizer ring and gear key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring and gear counter shaft Standard 1 0 2 0 mm 0 039 0 078 in Service limit 0 8 mm 0 032 in DN Key slot width b counter shaft Standard 10 0 10 2 mm 0 394 0 4015 in Service limit 10 45 mm 0 411 in e Using cylinder gauge 1 check inside diameter of counter shaft 5th gear 2 If measured value exceeds specification replace gear Counter shaft 5th gear diameter Standard 33 015 33 040 mm 1 2999
122. ling brake piston return spring be careful so that spring will not fall or tilt AUTOMATIC TRANSMISSION 4 A T 7B1 33 e When installing snap ring do not align lug 1 of retainer with opening in snap ring 2 e When installing brake discs brake plates and clutch backing plate refer to the first figure of CENTER SUPPORT in this section e Install clutch backing plate with its chamfered side facing brake disc 1 Clutch disc facing side e After installing each retaining backing plate ring measure movement of brake piston again If it is not within standard range it is possible that ring is not installed properly Then disassemble and reassemble again Standard movement of B1 brake piston 1 00 1 20 mm 0 039 0 047 in Standard movement of B2 brake piston 1 01 2 25 mm 0 040 0 088 in 7B1 34 AUTOMATIC TRANSMISSION 4 A T Planetary gears and output shaft A G16 and H25 engines only 6 One way clutch thrust washer 12 Front planetary ring gear 1 Inner shaft 7 Front planetary gear 13 Retaining ring 3 Reverse brake reaction plate 9 Reverse brake disc 15 Planetary sun gear 4 Retaining ring 10 Reverse brake backing plate 16 Bearing 5 One way clutch 11 Washer 17 Rear planetary ring gear 2 Retaining ring 8 Reverse brake plate 14 Rear planetary gear AUTOMATIC TRANSMISSION 4 A T 7B1 35 DISASSEMBLY 1 Remove front planetary gear assembly 1 from output shaf
123. ll make thrust clearance of bearing 0 1 mm 0 0039 in or less and install it Circlip thickness specification C Dmak Girlipihickness o 205 2 10 mm 0 0807 0 0826 in 4 210 2 15 0 0827 0 086n 2 25 2 30 0 0886 0 0905 in 2 20 2 25 0 0867 0 0885 in 5 230 2 35 0 0906 0 0925 in 7A1 26 MANUAL TRANSMISSION TYPE 2 3 Apply grease to bearing roller 1 and install it to input shaft 2 Grease 99000 25010 Main shaft assembly NOTE e Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear e Use new circlips on shaft for installation Don t reuse circlips 1 Assemble high speed synchronizer hub 3 sleeve 4 springs 1 and keys 2 according to the following proce FORWARD dure a Slide hub 3 in sleeve 4 so that wider flange side of sleeve 4 and boss side of hub 3 face opposite as shown in the figure also aligning hub slots with key location teeth of sleeve 4 b Insert keys 2 in hub slots with depression side of keys face center of hub 3 c Install springs 1 to internal circle of key locations with spring end gaps apart at angles about 120 degrees each other in order to apply spring tension equally to each key KAN NOTE Do not mix high and low speed synchronizer keys as dimensions are different B Key location teeth C Wider flange C gt C D Depression of key 2 Instal
124. lows a After cleaning 10 bevel gear teeth paint them with gear marking compound evenly by using brush or sponge etc b Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact c Bring painted part up and check contact pattern referring to following chart If contact pattern is not normal readjust or replace as necessary according to instruction in chart NOTE Be careful not to turn bevel gear more than one full revo lution for it will hinder accurate check A Paint gear marking compound evenly DIFFERENTIAL REAR 7F 17 TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY NORMAL Outer end Heel Drive side Coast sede Inner end Toe HIGH CONTACT Pinion is positioned too far from the center of drive bevel gear 1 Increase thickness of pinion height adjusting 1 1 Pinion shim and position pinion closer to gear center 2 Adjust drive bevel gear backlash to specifica tion LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height adjusting shim and position pinion farther from gear cen ter 2 Adjust drive bevel gear backlash to specifica tion If adjustment is impossible replace differential carrier 1 Check seating of bevel gear or differential case Check bevel gear for runout 2 If adjustment is impossible replace drive bevel gear amp pinion set or differen
125. m 1 8 Ib ft 1 Torque wrench 2 Differential case assembly 3 Aluminum plate FOR 4 DIFFERENTIAL PINION TYPE 1 After applying differential oil to side gear 4 pinions 5 pin ion shafts washer thrust washer 2 and spring washer 1 install them in differential left case 3 For correct installing direction of thrust washer 2 and spring washer 1 refer to the figure 2 When installing pinion shaft No 2 2 Shorter into differential case and pinion insert its a side into pinion joint 1 NOTE a is longer than b a gt b 3 Check pinion gear 1 for smooth rotation 2 Differential left case DIFFERENTIAL REAR 7F 9 4 In the same manner as described in Step 1 install thrust washer 2 spring washer 1 and side gear 4 3 Differential right case 5 Install differential right case 1 and then tighten bolts to specified torque A Cement 99000 32020 Tightening torque Differential case bolt a 41 N m 4 1 kg m 30 0 Ib ft 2 Differential left case 6 Install bevel gear in the same manner as step 5 of 2 differ ential pinion type 7 Check preload in the same manner as step 6 of 2 differential pinion type Differential side bearing 1 Press fit side bearing 1 with special tool and press Special tool A 09944 66020 2 Hold bearing press fitted in Step 1 with holder and press fit side bearing on the other side N
126. mary regulator valve sleeve so that its tip is posi tioned as it was before disassembly e Use new TCC lock up control valve gasket new solenoid gasket and new lower valve body plate gasket e Tighten shift solenoid valve bolt to specified torque Tightening torque Shift solenoid valve bolt 10 N m 1 0 kg m 7 5 Ib ft 1 Solenoid valve No 1 Shift solenoid valve e Tighten TCC lock up solenoid valve bolt to specified torque Tightening torque TCC solenoid valve bolt 5 5 N m 0 55 kg m 4 0 Ib ft 1 Solenoid valve No 2 TCC solenoid valve 7B1 52 AUTOMATIC TRANSMISSION 4 A T e Tighten pressure relief valve bolt to specified torque Tightening torque Pressure relief valve bolt 5 5 N m 0 55 kg m 4 0 Ib ft e Tighten lower valve body plate 1 TCC lock up control valve plate 2 flange bolt to specified torque Tightening torque Lower valve body and TCC control valve plate bolts 5 5 N m 0 55 kg m 4 0 Ib ft Unit Assembly 1 After applying A T fluid to new O rings install them to reverse brake piston 3 reaction sleeve 2 and secondary reverse piston 1 2 Install reverse brake piston assembly and brake piston return spring to transmission case using care not to damage O ring Then install snap ring 1 with special tool Special tool A 09926 98320 B 09941 84510 NOTE e Install so that opening in snap ring 1 will not align with any of 3 lugs of spring seat
127. n Spring e Measure free length Standard free length of forward clutch piston return spring 15 13 mm 0 596 in INSTALLATION 1 Apply A T fluid to forward input shaft O rings install forward clutch piston and piston return spring 2 to forward input shaft and then install return spring ring with special tool and hydraulic press Special tool A 09926 98310 NOTE e When installing return spring 2 be careful so that return spring 2 will not fall or tilt e Do not align opening in retaining ring 1 with lug of forward clutch piston return spring 2 at its retainer section CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform 2 Install clutch discs from the thinnest one to thicker ones to piston side and then install retaining clutch ring NOTE e Refer to the first figure of FORWARD CLUTCH in this section when installing each component e Do not match opening in retaining clutch ring and dent in forward clutch input shaft 3 Install bearing races and thrust bearing 1 Thrust bearing No 2 race 2 Thrust forward clutch bearing 3 Thrust rear race 7B1 24 AUTOMATIC TRANSMISSION 4 A T 4 Install forward clutch hub 3 direct clutch hub 2 and retain ing ring 1 to input shaft 4 in that order Direct clutch 5 Clutch disc 9 Direct clutch piston 6 Clutch plate 10 Direct clutch inner piston 3 Reta
128. n shaft assembly Check that input shaft assembly turns lightly 5 Fix with C ring to counter shaft rear bearing MANUAL TRANSMISSION TYPE 2 7A1 35 6 Install counter shaft 1 and rear bearing 2 to intermediate case NOTE e When installing bearing bring it so that its C ring side is at rear side of intermediate case as shown in the fig ure e When fitting of intermediate case and bearing is tight tap outer race of bearing lightly and evenly with plastic hammer 7 Install bearing plate 1 Tightening torque Bearing plate bolt a 19 N m 1 9 kg m 14 0 Ib ft 8 Install reverse idle gear 1 and shaft 2 9 Tighten reverse gear shaft bolt 1 to specification Tightening torque Reverse gear shaft bolt a 18 N m 1 8 kg m 13 5 Ib ft 7A1 36 MANUAL TRANSMISSION TYPE 2 10 Install reverse link stay 1 Tightening torque Reverse link stay bolt a 19 N m 1 9 kg m 14 0 Ib ft 11 Set ball 1 and thrust washer 2 to counter shaft 2 12 Install needle bearing 1 counter shaft 5th gear 2 and syn chronizer ring NOTE When setting synchronizer ring to sleeve of 5th gear align synchronizer key slot to key 13 Press fit 5th speed synchronizer dog 1 to counter shaft with press 2 and special tool Special tool B 09927 08220 MANUAL TRANSMISSION TYPE 2 7A1 37 14 Select circlip 1 that will make clearance in circlip groove 0 1 mm 0 0039 in or less
129. needle contacting surfaces rotating surfaces and replace with new ones as required NOTE Should abnormal noise be heard before disassembly it is necessary to carefully check needle contacting surface inside of each gear besides those parts shown in the fig ure 1 Main shaft 8 Reverse gear needle bearing 2 pieces 9 5th gear needle bearing 2 pieces e Check clearance a between synchronizer ring and gear key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring and gear Standard 1 0 1 4 mm 0 039 0 055 in Service limit 0 5 mm 0 019 in Key slot width b Standard 10 1 mm 0 397 in Service limit 10 4 mm 0 409 in e Using feeler gauge check clearance between sleeve 1 and shifter fork 2 and replace parts if necessary Clearance c between sleeve and shifter fork Maximum 1 0 mm 0 039 in e Check chamfered part of each sleeve for damage and exces sive wear and replace as necessary e Check each synchronizer key and synchronizer spring and replace as necessary e Check splined portions and replace parts if excessive wear are found 7A 16 MANUAL TRANSMISSION TYPE 1 Low and reverse scissors gear assemblies if equipped Check for the following items e Match mark 3 provided for reassembly should be almost at such
130. ness gauge 19 Check low gear clearance referring to Main Shaft Assem bly under Sub Assembly of Components Inspection in this section MANUAL TRANSMISSION TYPE 3 7A2 33 Counter shaft and reverse idle gear 1 Set inner race 2 to counter shaft front bearing 1 and press fit bearing with press 3 and special tool NOTE When installing bearing bring it so that its groove 4 for C ring as shown Special tool A 09940 54950 2 Select circlip that will make its thrust clearance 0 1 mm 0 0039 in or less and install it Circlip thickness specification ID mark Circlip thickness 2 00 2 05 mm 0 0785 0 0807 in 2 05 2 10 mm 0 0807 0 0826 in 2 15 2 20 mm 0 0847 0 0866 in 2 20 2 25 mm 0 0867 0 0885 in 2 25 2 30 mm 0 0886 0 0905 in 2 10 2 15 mm 0 0827 0 0846 in Special tool B 09900 06107 1 Circlip 2 Thickness gauge Input shaft bearing retainer and oil seal Press fit new oil seal 2 to bearing retainer 1 up to the specified position using special tool as shown in figure Apply grease to oil seal lip Grease 99000 25010 Special tool A 09913 75821 B 09924 84510 004 Oil seal installing position a 11 2 12 2 mm 0 44 0 48 in 7A2 34 MANUAL TRANSMISSION TYPE 3 Transmission rear case 1 Check that interlock cam component 1 moves smoothly in both turning direction and sliding
131. new one onto shaft using care so that it is installed in proper direction and position as shown in the figure Special tool K 09913 80112 Installing position a 39 5 mm 1 56 in 26 Install needle bearings 3 spacer 4 counter gear 2 steel balls 5 and washers 1 onto shaft 6 NOTE Washers must be installed with its oil slot side facing gear 7D 18 TRANSFER 4WD 27 Install counter shaft assembly into case If O ring 5 has been removed install new O ring onto shaft 3 and apply grease A Also install low gear needle bearing 1 G A Grease 99000 25010 gt ee 28 With circlip 2 placed on input gear 1 press fit input gear bearing 3 as shown Special tool D 09925 18011 E 09940 53111 H 09900 06107 29 Fix bearing with circlip 4 30 Install oil seal 1 to front case 2 so that end surface of oil seal becomes flush with that case Apply grease A to oil seal lip A Grease 99000 25010 Special tool B 09913 75520 31 Using special tool drive input gear assembly 2 into front case 1 Special tool I 09951 16080 32 Fix with circlip 1 by means of snap ring pliers Special tool J 09900 06108 TRANSFER 4WD 7D 19 33 Oil to rotating parts and clean mating surfaces of center 1 case and front case 2 34 Apply sealant C to mating surface of front case 2 evenly and put cases together NOTE e
132. ng and tighten housing bolt to specified torque Tightening torque Torque converter housing bolt a 35 N m 3 5 kg m 25 5 Ib ft Torque converter housing bolt b 58 N m 5 8 kg m 42 0 Ib ft 21 Apply grease to thrust front race and install it to O D clutch cylinder 1 Oil pump side 2 Over drive clutch cylinder side 22 Apply grease to front bearing assembly and install it to oil pump assembly Also apply A T fluid to new oil pump cover O ring and install it to oil pump assembly Then install oil pump assembly aligning bolt holes in O D case with those in transmission case oil pump assembly Apply seal packing to oil pump assembly bolts and tighten them by certain amount of torque at each time one after another till specified torque is attained Tightening torque Oil pump bolt a 22 N m 2 2 kg m 16 0 Ib ft 7B1 58 AUTOMATIC TRANSMISSION 4 A T 23 Apply 2 4 kg cm air pressure into fluid holes in the figure as numbered and check operation sound of each part 4 Direct clutch 5 B1 brake Second coast brake 6 B2 brake Second brake 7 Reverse brake 24 Take down transmission from stand and measure clearance in shaft direction by applying dial gauge 1 to output shaft as shown in the figure Standard clearance in shaft direction 0 3 0 9 mm 0 012 0 035 in 25 Check that inner shaft runs smoothly 26 Install parking lock pawl 1 pawl pin 2 and pawl spring
133. nizer low speed sleeve and hub assembly 14 5th gear 3 Synchronizer high speed ring 9 Low gear 15 5th gear washer 4 Synchronizer high speed sleeve and hub 10 Bearing washer 16 Rear bearing assembly 5 3rd gear 11 Main shaft bearing 17 Main shaft 6 2nd gear 12 Reverse gear NOTE e Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear e Use new circlips on shaft for reinstallation Don t reuse used circlips 1 Fit sleeve to low speed hub 1 place 3 synchronizer keys 4 in it and set synchronizer spring 3 Refer to the figure for proper installing direction of hub 1 sleeve 2 and springs 3 Synchronizer key 4 has no spe cific direction for installation NOTE When installing each synchronizer spring insert its hooked end to hub hole and put it toward right A Thick 2nd and front side B Thin Low and rear side C Punch mark Low and rear side MANUAL TRANSMISSION TYPE 1 7A 23 2 Install needle bearing 2 2nd gear 3 and 2nd synchronizer ring to main shaft 1 3 Press fit low speed sleeve and hub assembly 2 onto main shaft 1 with press 3 UT Special tool Kam A 09927 08210 i e 1 WU 4 Insert low gear bush 1 and set synchronizer ring 3 nee dle bearing 2 and low gear 4 5 Set steel ball 1 and washer 2 3 Low gear 6 Using special tool and press press fit bearing 1 Special tool B 09925
134. nner shaft 2 Gear shift control lever 15 High gear shift shaft 28 Locating screw Apply thread lock 99000 32020 to all around thread part of screw 3 Clamp 16 High speed gear shift fork 29 Locating spring 4 Gear shift lever case 17 Low speed gear shift fork 30 Locating ball 1333B 5 Control lever locating bolt 18 Reverse gear shift yoke 31 Locating roller No 3 Apply thread lock 99000 32020 to all around thread part of bolt 7A1 6 MANUAL TRANSMISSION TYPE 2 6 Case plate 19 Low gear shift shaft O 32 Locating roller No 2 Apply sealant 99000 31110 to mating Apply grease 99000 25010 to all surface to lever case around part of roller 7 Gear shift arm 20 Reverse gear shift shaft 33 Locating roller No 1 8 Spring pin 21 5th gear shift shaft 34 Reverse gear shift link comp 9 Gear shift lever case plate screw 22 Circlip 35 Shift fork bolt Apply thread lock 99000 32020 to all Apply thread lock 99000 32020 to all around thread part of screw around thread part of bolt 10 Bush 23 5th gear shift fork Q Tighting torque 11 Gear shift lever 24 Gear shift shaft inner lever X Do not reuse 12 Gear shift shaft 25 Gear shift shaft inner bolt Apply thread lock 99000 32020 to all around thread part of bolt 13 Case plug 26 Gear shift shaft inner plug Apply thread lock 99000 32020 to all around thread part of plug MANUAL TRANSMISSION TYPE 2 7A1 7 Unit Disassembly Gear Shift L
135. ockwise NOTE e Converter placed with its flange upright does not fit for this inspection e For proper checking position converter with its flange horizontal e Turn stator inner race clockwise as quickly as possible with finger then turn reversely at the same speed and feel difference of inertia 1 Stator inner race Should turn freely clockwise only Do Not Replace Converter for Following Con ditions 1 The fluid has an odor is discolored and there is no evidence of metal particles There is no indication of existence of inter nal damage or oil pump damage Dump out as much fluid as possible from the converter and replace only the oil pump screen in the pan 2 A small amount of wear sometimes referred to as fretting wear appears on the hub where the oil pump drive gear is located A certain amount of such wear is normal for both the hub and oil pump gear Neither the converter nor the oil pump assembly should be replaced 7B1 4 AUTOMATIC TRANSMISSION 4 A T Unit Repair Precautions As the automatic transmission consists of high precision components the following cautions should be strictly observed when handling its parts in disassembly and reassembly e Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during dis mounting and remounting e Select a clean place free from dust and dirt for overhauling e Place a rubber mat on the work bench to protect parts
136. om lower case 17 Remove circlip 3 of counter shaft 1 front bearing 2 and pull out bearing 2 by using puller Hates Special tool AKSER OY a B 09913 60910 18 Remove circlip 2 friction gear retainer 3 friction gear spring 4 friction gear 5 and pin 6 from counter shaft 1 in that order MANUAL TRANSMISSION TYPE 1 7A 11 Sub Assembly Input shaft 1 Take out oil seal 1 from input shaft oil seal retainer 2 and install new oil seal 1 with special tool and hammer up to case surface Unless oil seal 1 is leaky or its lip is excessively hardened replacement is unnecessary Special tool A 09913 84510 2 Remove circlip of input shaft 1 and pull out bearing 2 with bearing puller 3 and press as necessary NOTE Sealed bearing must not be washed Replace it with new one when required 3 When installing bearing 1 bring it so that its groove for cir clip is in the front and press fit with special tool and press Special tool B 09925 18011 4 After fitting circlip 1 air blow lubrication oil hole 2 7A 12 MANUAL TRANSMISSION TYPE 1 Main shaft 1 After removing needle bearing for input shaft at the front end of main shaft pull out high speed sleeve from its hub 3 and remove 3 synchronizer keys 2 Remove circlip in front of hub 3 and pull off hub 3 with special tool then take out synchronizer springs Special tool A 09913 61510 gd a
137. omponent 1 Components Inspection Sub Assembly Input shaft assembly Check clearance a between synchronizer ring and gear key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring and gear input shaft Standard 1 0 2 0 mm 0 039 0 078 in Service limit 0 8 mm 0 032 in Key slot width b input shaft Standard 10 0 10 2 mm 0 394 0 401 in Service limit 10 45 mm 0 411 in 7A1 20 MANUAL TRANSMISSION TYPE 2 Main shaft assembly Check clearance a between synchronizer ring and gear key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth ips Clearance a between synchronizer ring and gear Main shaft Standard 1 0 2 0 mm 0 039 0 078 in Service limit 0 8 mm 0 032 in Key slot width b Main shaft 1st 2nd Standard 12 2 12 4 mm 0 481 0 488 in Service limit 12 65 mm 0 498 in 3rd Standard 10 0 10 2 mm 0 394 0 401 in Service limit 10 45 mm 0 411 in Fy a ji A Z p DIDIDA e Check clearance between fork and sleeve If clearance exceeds limit replace fork and sleeve Clearance between fork and sleeve Standard 0
138. or leakage and its lip for excessive hardness If either is found replace Also check corresponding surface of shaft where oil seal lip contacts Correct or replace as necessary e Check gear tooth surface of soeedometer drive gear Replace if it is damaged TRANSFER 4WD 7D 11 Put the synchronizer outer ring 1 inner ring 3 center cone 2 and inner ring together and then measure the step difference b between the outer ring 1 and the inner ring 3 And also check key slot or boss width c in synchronizer outer ring 1 and each chamfered tooth of gear and syn chronizer ring and replace with new one if necessary Also check gear tooth Difference b between the outer ring and the inner ring Standard 1 0 1 4 mm 0 039 0 055 in Service limit 0 5 mm 0 019 in Slot or Boss width c in synchronizer outer ring Standard 10 1 mm 0 397 in Service limit 10 4 mm 0 409 in e Check chamfered part of each sleeve 1 for damage and excessive wear and replace as necessary e Using feeler gauge check clearance d between sleeve 1 and shift fork 2 and replace parts if necessary Clearance d between sleeve and shift fork Maximum 1 0 mm 0 039 in e Check each synchronizer key and synchronizer spring and replace as necessary e Check splined portions and replace parts if excessive wear is found Assembly 1 Using press and special tool press fit needle bearing into
139. ow synchronizer ring needle bearing and low gear bush 1 12 Using bearing puller 4 and press pull out low speed sleeve and hub assembly 2 2nd gear 3 and 2nd synchronizer ring all together IK Ca NOTE If bush can t be pulled out by hand at step 11 pull off sleeve and hub together by using press 13 Remove sleeve from hub and then take off synchronizer keys and springs 7A 14 MANUAL TRANSMISSION TYPE 1 Upper case and shifter 1 Remove back up light switch 2 and locating spring bolts 3 from upper case 1 2 Take out locating springs and locating balls 3 Remove 2 spring pins and pull out low speed gear shift shaft 3 and high speed gear shift shaft 2 in that order 4 Pull out reverse gear shift shaft 1 then disconnect fork from shaft 1 by removing spring pin Special tool A 09922 85811 NOTE Make sure that remaining gear shift shafts are all neutral position when removing a gear shift shaft 5 Take out rubber plug and 2 interlock balls from case 6 Remove interlock pin from high speed gear shift shaft Component Inspection Counter Shaft and Main Shaft Inner Parts e Check tooth surface of gear and rotation of bearing 1 and replace with new one if necessary As long as no abnormal condition such as noise exists before removal replacement is unnecessary i pee ie AER aZ A 4 O S cy MANUAL TRANSMISSION TYPE 1 7A 15 e Inspect needle bearings and
140. pring bolt to specified torque Tightening torque Detent spring bolt 5 5 N m 0 55 kg m 4 0 Ib ft Ce 14 FR Va gt I AG 7B1 44 AUTOMATIC TRANSMISSION 4 A T ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points e Coil outer diameter and free length of each valve spring should be as listed below Be sure to use each one of correct size Coil outer diameter and free length of each valve spring Free length Secondary regula 17 43 mm 71 27 mm 2206 in Cut back valve 6 85 mm 23 00 mm 0905 in Throttle valve sec 8 56 mm 18 86 mm ondary spring 0 337 in 0 743 in Throttle valve pri 10 90 mm 39 55 mm mary spring 0 429 in 1 557 in e Install as many throttle valve compensating rings as written down when disassembled e Tighten throttle cam bolt 1 to specified torque Tightening torque Throttle cam bolt a 7 5 N m 0 75 kg m 5 5 Ib ft e Tighten pressure relief valve bolts 1 to specified torque Tightening torque Pressure relief valve bolt b 5 5 N m 0 55 kg m 4 0 Ib ft AUTOMATIC TRANSMISSION 4 A T 7B1 45 Rear upper valve body 1 3 2 kickdown control valve plug 5 Rear upper valve body 9 Shift valve plug 13 Shift valve spring 2 Clutch sequence valve 10 2 3 shift valve 14 3 4 shift valve 11 i i 3 Reverse brake sequence valve spring 7 Gasket Shift valve spring 15 Shift valve spring 4 Needle roller
141. r 7E 7 Special TOON ua e 7E 19 ACUO ane 7E 7 Subassembly Adjustment and ROSS ua 7E 8 7E 2 DIFFERENTIAL FRONT General Description Component 1 Flange nut 8 Front bearing 15 Actuator DIFFERENTIAL FRONT 7E 3 Unit Repair Disassembly Unit 1 Remove front drive shaft 1 by using plastic hammer 2 Differential housing 2 Remove 8 bolts for fastening differential carrier 2 of which are reamer bolts and then take differential assembly out of housing 1 Bolt 2 Reamer bolt 3 Set special tool on vise 1 securely Special tool A 09944 76010 4 Using 4 bolt amp nut sets set differential assembly onto differ ential carrier holder and put identification marks on differen tial side bearing caps 6 Remove differential inner hose and actuator bracket bolt 5 Take off differential side bearing lock plates 4 and differen tial side bearing caps 6 removing their bolts and then take out bearing adjusters 5 side bearing outer races and drive bevel gear with differential case 3 6 Turn differential assembly together with special tool by 90 degrees and grip it with vise again Special tool A 09944 76010 1 Differential carrier 2 Drive bevel gear assembly A Identification mark 7E 4 DIFFERENTIAL FRONT 7 Remove air inlet union 2 1 Differential carrier 8 Hold universal joint flange with special tool and then remove flange nut by using power wrench Special tool
142. r shift fork 12 5th amp reverse guide shaft 22 Gear shift shaft 32 Gear shift control lever 3 High and low speed gear 13 Reverse gear shift fork 23 Gear shift lever 33 Clamp shift fork bolt 4 Interlock pin 14 Locating screw O 24 Bush 34 Gear shift control lever Apply grease 99000 25010 to knob whole area of bush 5 High speed gear shift shaft 15 Compression spring 25 Spring pin 35 Breather hose 6 High speed gear shift fork 16 Ball 26 Gear shift arm 36 Breather hose 3way joint TA 7 Straight pin 17 Gear shift inner shaft 27 Case plate 37 Breather plug Apply grease 99000 25010 to all around part of pin 8 Circlip 18 Gear shift shaft inner lever 28 Gear shift lever case plate Q Tightening torque screw 9 5th gear shift shaft 19 Locating spring 29 Gear shift lever case 10 5th gear shift fork 20 Reverse gear shaft arm 30 Control lever locating bolt Apply thread lock 99000 32110 to all around thread part of bolt MANUAL TRANSMISSION TYPE 3 7A2 7 Unit Disassembly Gear Shift Lever Case 1 Remove case plate 2 With case supported with soft jawed vise remove lever locat ing bolts 6 NOTE Use aluminum plates between vise and case to protect case against damage 3 Using special tool drive spring pin 2 into gear shift arm 5 as far as the position shown in the figure CAUTION When driving spring pin 2 use care not to damage gear shift lever case 1 Special tool A
143. re it is also necessary to know reading of short pointer Special tool A 09900 20606 B 09926 78311 D 09951 16070 E 09922 77250 4 differential pinion type 5 Obtain adjusting shim thickness by using measured value by dial gauge which represents c in Drive bevel pinion in this section in the following equation 97 2 differential pinion type or 102 4 differential pinion type in above equation is a b of mounting dummy spe cial tool as shown in Drive bevel pinion in this section Neces 97 2 differential Measure lt Dial gauge sary shim _ pinion type or piles peas ment thickness 102 4 differen value c printed on Tf tial pinion type pinion e A 2 differential pinion type B 4 differential pinion type 6 Select adjusting shim s 2 closest to calculated value from among following available sizes and put it in place and then press fit rear bearing 1 Calculated valve g Closest value to f refer to Step 5 Special tool G 09925 18011 H 09927 66010 Available shim thickness 1 12 1 15 1 18 1 21 1 24 1 27 1 30 and 0 3 mm 0 044 0 045 0 046 0 047 0 048 0 049 0 050 and 0 012 in 3 Bevel pinion DIFFERENTIAL REAR 7F 13 7 With new pinion spacer 3 inserted as shown in the figure install front bearing 5 to differential carrier 4 NOTE e Make sure to use new spacer for reinstallation e
144. rennrrr 7B1 38 Conditions sreoorversvervsversrversversseessseerssennsnn 7B1 3 aie upper ve el seeevteeaneeennenensetan ee ear upper valve bOdY 000e Unit Repair EE 7B1 4 Lower valve body 7B1 48 Precautions ER korrereserererererernrenn 7B1 4 Unit ASSEMbly csceccseecseesseeseessseessessseesees 7B1 52 Part Inspection and Correction Table 7B1 4 Bearing and Race Installation Unit Disassembly rrrrannnrrnrnnnnnnnrvrnnnnnnnvrnn 7B1 5 Diagram 7B1 65 Sub Assembly Repair rrrrrnnnnannnnnnnnrrvnnne 7B1 10 EE VEN EE Rae eens oY Moi 4 7B1 10 Tightening Torque Specification sisis 21 00 Overdrive Planetary gear side 7B1 13 Required Service Material 000 7B1 66 Overdrive Case side 22nnnnnnnnnnnns 7B1 17 Special TOO sn 7B1 67 7B1 2 AUTOMATIC TRANSMISSION 4 A T General Description When repairing automatic transmission it is necessary to conduct the on vehicle test to investigate where the cause of the trouble lies first Then whether overhaul should be done or not is determined If the transmission is disassembled without such preliminary procedure not only the cause of the trouble would be unknown but also a secondary trouble may occur and often time would be wasted a m s a rer tg t r gt 1 I mea gt PP Ab Bl A A ET ge Fa I at FL Tag z5 eee i gt 6 Forward clutch input s
145. rse gear shift limit yoke 4 Drive in spring pin double for shift lever 5 Drive in spring pin single long for return spring 6 Fit straight end of shift limit spring 2 into line groove in shift limit yoke 1 and with its other hooked end turned in its winding direction by about 90 from its free state hook it on spring pin 4 7 Drive in spring pin for shift arm MANUAL TRANSMISSION TYPE 1 7A 19 8 Press fit case plug 1 into case A Caulking 9 After applying grease A install select guide pins select return springs and spring bolts 2 and torque them to speci fication A Grease 99000 25010 Tightening torque Select return spring bolt a 35 N m 3 5 kg m 25 5 Ib ft NOTE Double coil spring is required at 5th Reverse select side 10 Clean mating surfaces of both case plate and case apply sealant B to case side evenly mate them and fasten with screws 5 B Sealant 99000 31110 Tightening torque Shift lever case plate screws b 9 N m 0 9 kg m 6 5 Ib ft 11 If reverse gear shift limit bolt 1 has been removed apply thread lock cement C to bolt then install and torque it to specification C Thread lock cement 99000 32020 Tightening torque Reverse gear shift limit bolt c 23 N m 2 3 kg m 17 0 Ib ft 3 Inner and outer spring Double coil spring 4 Outer spring 7A 20 MANUAL TRANSMISSION TYPE 1 12 Install gear shift lev
146. rse synchronizer sleeve 3 24 Drive spring pin 1 into 5th gear shift fork 2 and shaft 3 up to 5th gear shift fork 2 surface using plastic hammer 25 Install new circlip to groove of shaft to fix 5th gear shift shaft 2 and 5th amp reverse guide shaft 3 using lever 4 or the like and hammer 26 Insert interlock pin 1 to intermediate case 2 using magnet 3 MANUAL TRANSMISSION TYPE 3 7A2 43 27 Apply grease to straight pin 1 and install straight pin 1 to low speed gear shift shaft 2 A Grease 99000 25010 28 Install low speed gear shift fork 1 and low speed gear shift shaft 2 29 Insert interlock pin 1 to intermediate case 2 using magnet 3 30 Install high speed gear shift fork 1 and high speed gear shift shaft 2 31 Fix with new circlips 1 to high speed gear shift shaft 2 and low speed gear shift shaft 3 using lever 4 or the like and hammer 7A2 44 MANUAL TRANSMISSION TYPE 3 32 Install new low speed gear shift fork bolt 1 and high speed gear shift fork bolt 2 and tighten bolts to specified torque Tightening torque Low and high speed gear shift fork bolt a 20 N m 2 0 kg m 14 5 Ib ft 33 Install locating balls 1 locating springs 2 and new locating screws 3 Tightening torque gt 7 Locating screw Je A ONA a 19 N m 1 9 kg m 14 0 Ib ft SY y DI 3 a Gy 7 34 Place intermediate case assembly 1 upright as
147. sleeve 7 and hub 8 all together 9 Output rear shaft 20 Using plastic hammer 2 drive out output rear shaft assem bly 1 with bearing Output low gear and reduction clutch hub also come off as they are installed to shaft 21 Pull off circlip from output rear shaft and remove reduction clutch hub 1 by using puller 2 and press Then pull out output low gear and needle bearing 22 Using puller 3 and press remove output rear shaft No 1 bearing 2 from shaft 1 23 Remove oil seal from center case 1 24 Using plastic hammer drive out output front shaft 2 together with bearings CAUTION If oil seal remains in center case be careful not to dam age oil seal by hitting Use drive punch for hammering 7D 8 TRANSFER 4WD 25 Take off bearings 1 3 from shaft by using press and puller 2 Removal of front side bearing requires special tool addi tionally as shown in the figure Special tool E 09925 98221 26 To remove needle bearing 2 from center case 1 combine special tools as shown in the figure and press them Special tool F 09913 84510 G 09941 64511 27 Remove oil seal from rear case 1 And then using special tools and press remove needle bearing 2 from rear case CAUTION Be careful not to damage oil seal if it remains in rear case Special tool F 09913 84510 G 09941 64511 28 Using special tool remove circlip 3 of input gear 1 from front cas
148. so aligning hub slots with key location teeth of sleeve 4 A Small diameter boss a lt b B key location teeth C Rod D Input shaft side E Chamfered side 2 Assemble 3rd gear 1 synchronizer inner ring 2 synchro nizer cone ring 4 and synchronizer outer ring according to the following procedure a Install the synchronizer inner ring 2 to 3rd gear 1 b Install synchronizer cone ring 4 to 3rd gear 1 NOTE Fit protrusion 5 of synchronizer cone ring 4 into groove 3 of 3rd gear 7A2 28 MANUAL TRANSMISSION TYPE 3 c Install synchronizer outer ring 1 to 3rd gear 2 d Align protrusion of synchronizer outer ring 1 into slot of synchronizer hub 2 and then attach high speed synchro nizer sleeve and hub assembly to 3rd gear 3 Also aligne protrusion 4 of synchronizer inner ring and dent 5 of high speed synchronizer hub 3 Install needle bearing 2 to main shaft 1 and press fit 3rd gear high speed synchronizer sleeve and hub assembly 3 which was assembled in step a through d to main shaft 1 using special tool and press Special tool A 09940 53111 4 Select circlip 1 that will make thrust clearance of high speed synchronizer hub 0 1 mm 0 0039 in or less and install it Circlip thickness specification 2 05 2 10 mm 0 0808 0 0826 in 0749 in D 1 1 95 2 00 mm 0 0768 0 0787 in G 2 10 2 15 mm 0 0826 0 0846 in
149. speed synchronizer hub 2 14 Install synchronizer cone ring 1 and synchronizer inner ring 2 NOTE Fit protrusion 3 of synchronizer inner ring 2 into dent 4 of low speed synchronizer hub 5 15 Install low gear 1 to main shaft 2 NOTE e Fit protrusion 3 of synchronizer cone ring 5 into groove 4 of low gear 1 e After installation check synchronizer outer ring 5 moves in circumferential direction 16 Install pin 1 and low gear thrust washer 2 to main shaft NOTE Be sure to engage cut 3 in low gear thrust washer 2 to pin 1 7A2 32 MANUAL TRANSMISSION TYPE 3 17 Press fit main shaft bearing 1 and 5th gear 3 with special tool and press 2 NOTE e Bring bearing so that its groove for circlip is in the rear e Bring 5th gear 3 so that its small diameter boss a is in the rear Special tool C 09940 51710 A Rear side a lt b 18 Select circlip 1 that will make its thrust clearance 0 1 mm 0 0039 in or less and install it Circlip thickness specification Circlip thickness mark DF 2 80 2 85 mm 0 102 0 1122 in Ef 2 85 2 90 mm 0 4122 0 1142 in FF 2 90 2 95 mm 0 4142 0 1161 in 6 F295 3 00 mm 0 4161 0 1181 in H 3 00 3 05 mm 0 1181 0 1201 in K 3 10 3 15 mm 0 1220 0 1240 in m 320 325 mm 0 1260 0 1280 in N 325 330 mm 0 1280 0 1299 in P 330 335 mm 0 1299 0 1319 in 2 Thick
150. spring specification G16 engine Usedfor Piston outer diameter a Direct clutch accumulator 2 31 80 31 85 mm Poet Gasz 12samy Loversping c Forward clutch accumulator 1 31 80 31 85 mm C U 621254 a Second brake accumulator 3 34 80 34 85 mm Me 1370 1372 Accumulator piston and spring specification J20 engine Used for Piston outer diameter a Direct clutch accumulator 2 31 80 31 85 mm Poet 291200 Lewerspring L o Forward clutch accumulator 1 31 80 31 85 mm een a Lomrsig Second brake accumulator 3 34 80 34 85 mm Me ugro 13720 Accumulator piston and spring specification H25 engine Usedfor Piston outer diameter a Spring free length b Direct clutch accumulator 2 31 80 31 85 mm Upper spring 38 00 mm 1 496 in 1 252 1 254 in 30 00 mm 1 181 in Forward clutch accumulator 1 31 80 31 85 mm 25212800 Second brake accumulator 3 34 80 34 85 mm ee tasty AUTOMATIC TRANSMISSION 4 A T 7B1 61 34 Lift valve body a little and install nipple of throttle cable to throttle valve cam 35 After confirming that accumulator piston is pushed all the way down match pin of manual shift lever with groove in manual valve 36 Fix valve body by using bolts with each nominal length as shown in the figure and tightening to specified torque Tightening torque Valve body bolt 10 N m 1 0 kg m 7 5 Ib ft Valv
151. staller 09922 85811 Spring pin remover 09951 16080 Bearing installer MANUAL TRANSMISSION TYPE 2 7A1 1 SECTION 7A1 MANUAL TRANSMISSION TYPE 2 CONTENTS General Description saassasnannnnennnnnveveveenen 7A1 2 Main shaft assembly rrrrrnnnnrnnnnnnnnn 7A1 20 Identification of Transmission Type 7A1 2 Counter shaft and reverse idle gear 7A1 22 COMPONENTS iniaiaiai es 7A1 2 Unit Assembly rnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnvenenenn 7A1 24 Input and Counter Shaft Components 7A1 3 Gear Shift Lever Case n 7A1 24 Transmission Case Components 7A1 4 SUD ASSOMDIY cccscccesesesesceseseseseseseseesees 7A1 25 Gear Shifter Components n ssrororvrvrvrvren 7A1 5 Input shaft assembly 0seeeeeeee 7A1 25 Unit Disassembly nnnnnnnnnnnnnvvrvvvnnnnnnnnnnnnnnnner 7A1 7 Main shaft assembly snnnnnnnnnnvnnnnnnne 7A1 26 Gear Shift Lever CaSe 7A1 7 Counter shaft and reverse idle gear 7A1 30 Transmission Unit sveverevvrvererrrverererennn 7A1 7 Input shaft bearing retainer and oil Sub Assembly rsrrvrrvrvrrvenvrvrvrrverneversenenen 7A1 16 SVT 7A1 31 Input shaft assembly rsrrvrrvrrvervesren 7A1 16 Transmission rear case 7A1 31 Main shaft assembly ororororonrrenren 7A1 16 Transmission intermediate case and Counter shaft amp reverse idle gear 7A1 17 front case location of knock and Input shaft bearing re
152. stepped wear Replace AUTOMATIC TRANSMISSION 4 A T 7B1 5 Unit Disassembly 1 Extract torque converter And remove oil filler tube and dip Stick CAUTION Remove torque converter as much straight as possible Leaning it may cause to damage oil seal lip 1 Torque converter 2 Converter housing 2 Remove speed sensor 1 3 Remove 6 adapter case fixing bolts and then remove adap tor case 2 NOTE Use care not to cause damage to oil seal 4 Remove gasket 5 Remove shift switch 1 6 Remove C ring 1 and then remove speed sensor rotor 2 NOTE Use care not to loose rotor stop key 7B1 6 AUTOMATIC TRANSMISSION 4 A T 7 Remove oil pump 5 by using puller 1 NOTE Use care not to cause damage to shaft bushing surface 2 8 Remove bearing at the real of oil pump 5 9 Remove O ring from oil pump 5 10 Holding input shaft 4 by hand remove converter housing 3 11 Check dimensions of overdrive O D case surface and clutch cylinder surface for reassembly 12 Remove overdrive O D clutch assembly by holding input shaft 3 13 Remove O D case bearing and bearing race NOTE Confirm direction of bearing and bearing race for reas sembly 2 Clutch cylinder 14 Remove oil pan 1 NOTE e Hold oil pan with oil pan side down to prevent foreign material in oil pan from entering valve body e If iron powder is found it is possible that bearing gear
153. synchronizer hub 1 in protrusion of synchronizer outer ring 2 as shown in the figure Also aligne protrusion 4 of synchro nizer inner ring and dent 5 of low speed synchronizer hub 9 Install the needle bearing to the 2nd gear then as then figure shows press fit 2nd gear low speed synchronizer sleeve and hub assembly 1 which was assembled in step a through d into main shaft 2 using a special tool Press fit low speed sleeve and hub assembly with special tool and press 3 Special tool A 09944 78210 10 Select circlip 1 that will make thrust clearance of low speed synchronizer hub 0 1 mm 0 0039 in or less and install it Circlip thickness specification Circlip thickness A 2 30 2 35 mm 0 0906 0 0925 in gt B 2 35 2 40 mm 0 0925 0 0945 in 2 40 2 45 mm 0 0945 0 0965 in D 2 48 2 50 mm 0 0965 0 0984 in E 250 255 mm 0 0984 0 1004 in F 255 2 60 mm 0 1004 0 1024 in 6 2 60 2 65 mm 0 1024 0 1043 in Special tool A 09900 06107 11 Check 2nd gear thrust clearance referring to Main Shaft Assembly under Sub Assembly of Component Inspec tion in this section 12 Install spacer 1 and needle bearing 2 to main shaft 3 MANUAL TRANSMISSION TYPE 3 7A2 31 13 Install synchronizer outer ring 1 to low speed synchronizer hub 2 NOTE Fit protrusion 3 of synchronizer outer ring 1 into groove 4 of low
154. synchronizer ring 4 moves in circumferential direction 16 Press fit main shaft bearing 1 and 5th gear with special tools and press 2 NOTE Bring bearing so that its groove for circlip is in the rear Special tool C 09940 51710 or 09925 18011 7A1 30 MANUAL TRANSMISSION TYPE 2 17 Select circlip 1 that will make its thrust clearance 0 1 mm 0 0039 in or less and install it Circlip thickness specification Dmak Circlip thickness 2 67 2 72 mm 0 1052 0 1070 in 2 73 2 78 mm 0 1075 0 1094 in 2 79 2 84 mm 0 1099 0 1118 in D 285 290 mm 0 1123 0 1141 in E 291 296 mm 0 1146 0 1165 in ZF 2 97 3 02 mm 0 1170 0 1188 in G 3 03 3 08 mm 0 1193 0 1212 in HH 3 09 3 14 mm 0 1217 0 1236 in 3 15 3 20 mm 0 1241 0 1259 in K 3 21 3 26 mm 0 1264 0 1283 in 3 27 3 32 mm 0 1288 0 1307 in 2 Thickness gauge 18 Check low gear clearance referring to Main Shaft Assem bly in this section Counter shaft and reverse idle gear 1 Fit sleeve 4 to counter shaft 5th gear 3 place 3 synchro nizer keys 2 in it and then set synchronizer springs 1 Refer to the figure for proper installing direction of gear sleeve and springs Also note that key has specific installing direction A Reverse side front B 5th side C Key position D 5th side thick 2 Set inner race 2
155. t assembly 2 2 Remove rear planetary thrust washer 1 reverse brake backing plate 2 reverse brake disc 3 and reverse brake plate 4 from front planetary gear assembly 3 Remove reverse brake reaction plate 2 from front planetary gear 1 4 After removing retaining ring 1 remove one way clutch 2 and one way clutch rear thrust washer 3 4 Front planetary gear 7B1 36 AUTOMATIC TRANSMISSION 4 A T 5 After removing retaining ring 1 remove front planetary ring gear 2 thrust bearing and rear planetary race 6 Remove rear planetary thrust washer 1 rear planetary gear 2 and rear planetary sun gear 3 7 After removing retaining ring 2 from inner shaft 1 remove rear planetary ring gear 3 and thrust bearing assembly ASSEMBLY Assemble components by reversing disassembly procedure and noting following points e Refer to the first figure of PLANETARY GEARS AND OUT PUT SHAFT when installing each component e Check seal sleeve ring for damage before installation and replace if damaged e Install planetary sun gear as shown in the figure e Fit retaining rings into groove securely AUTOMATIC TRANSMISSION 4 A T 7B1 37 Install one way clutch as shown in the figure 1 Front planetary gear side e Install reverse brake reaction plate 2 to front planetary gear 1 With reverse brake reaction plate 2 fixed stationary turn front planetary gear 1 clockwise to check th
156. tainer and oil plug EN mpanmaeenee ene 7A1 33 SOA eet eee ae ee 7A1 18 Transmission Unit seseeeeeseteseeeereeeeseees 7A1 33 Transmission rear CaSe rrrrrrrrrnnnnnnrr 7A1 18 Tightening Torque Specification 7A1 45 Components Inspection 00eeeee 7A1 19 Required Service Material 000 7A1 45 Sub Assembly ccccccecceecceeeeceeeeeeseeeeeseeess 7A1 19 Special TOG visit sistincs Gdansk 7A1 46 Input shaft assembly cccceeeeeeeees 7A1 19 7A1 2 MANUAL TRANSMISSION TYPE 2 General Description Identification of Transmission Type Refer to Identification of Transmission Type in Section 7A Components 15 T 12 16 m LI AI Lg OF IG I PIL kter aT TL A Wo EE Pi MANUAL TRANSMISSION TYPE 2 7A1 3 Input and Counter Shaft Components F 32 0 18 N m 1 8 kg m oO 1 Input shaft 25 Thrust washer 7 Synchronizer spring 19 Needle bush 31 Reverse gear shift plate 8 Synchronizer key 20 Main shaft bearing 32 Reverse gear shaft bolt 9 High speed hub 21 5th gear 33 Input shaft bearing roller AGR Apply grease 99000 25010 to all around part of roller 10 High speed sleeve 22 Counter shaft front bearing Q Tighting torque 11 3rd gear 23 Counter shaft X Do not reuse 12 Needle bearing 24 Counter shaft rear bearing 7A1 4 MANUAL TRANSMISSION TYPE 2 Transmission C
157. te case 19 Return spring reverse bolt AGR Apply grease 99000 25010 to oil seal Apply sealant 99000 31110 to mating sur lip face to translation front and rear case 4 Input shaft bearing retainer bolt 12 Main and countershaft bearing retainer 20 Interlock cam plug 5 Transmission front case 13 Main and countershaft bearing retainer bolt 21 Interlock cam pin y Apply thread lock 99000 32110 to all around thread part of bolt 6 Oil drain plug 14 Countershaft gutter 22 Plug Do not drain transmission oil from this plug 7 Oil filler level plug 15 5th reverse interlock cam component Q Tightening torque 8 Back up light switch 16 Return spring low bolt 7A2 4 MANUAL TRANSMISSION TYPE 3 Input and Counter Shaft Components 13 3rd gear synchronizer inner ring 29 5th gear KIT Do not reuse 14 3rd gear 30 Low gear synchronizer inner ring transmission oil 15 Needle bearing Low gear thrust washer 16 Main shaft 32 Countershaft front bearing MANUAL TRANSMISSION TYPE 3 7A2 5 Gear Shifter Components SG 14 KA UV 18 5 N m 1 85 kg m 19 16 on 20 EE oS 1 95 kg m Ve ae _ BARO w 07 A cK i So 4 st j Laas 6 of 15 tl 14 29 V 18 5 N m 1 85 kg m NY i p 31 9 F 23 nm 2 3 kg m 7A2 6 MANUAL TRANSMISSION TYPE 3 1 Low speed gear shift shaft 11 Spring pin 21 Case plug 31 Gear shift lever case bolt 2 Low speed gea
158. tial carrier Replace drive bevel gear amp pinion set or differential case 7F 18 DIFFERENTIAL REAR 10 Upon completion of gear tooth contact check in Step 8 caulk flange nut 2 with caulking tool 1 and hammer Fastening part Bevel gear bolts Bearing cap bolts Lock plate bolts Differential case bolts Om 44 3 0 Required Service Material Recommended SUZUKI product Part Number Thread lock cement THREAD LOCK CEMENT e Bevel gear bolts SUPER 1333B e Differential case bolts 99000 32020 Lithium grease SUZUKI SUPER GREASE A e Oil seal lips 99000 25010 Sealant SUZUKI BOND NO 1215 e Rear differential drain plug 99000 31110 e Mating surface of differential housing e Mating surface of rear axle housing 09900 20606 Dial gauge 09922 77250 Attachment 09922 75222 Preload adjuster 09926 68310 Bearing installer DIFFERENTIAL REAR 7F 19 Special Tool 09900 20701 Magnetic stand 09913 75510 Bearing installer 09922 85811 Spring pin remover 09926 78311 Bevel pinion mounting dummy 09913 61510 09913 65135 Bearing puller Bearing puller 09913 85230 09922 66020 Bearing removing jig Flange holder 09924 74510 09925 18011 Installer attachment Bearing installer 09927 66010 J 23082 01 09928 06010 002 Oil pump aligner Differential torque checking tool 7F 20 DIFFERENTIAL REAR 09930 40113 09930 40120 Rotor holder 09951 16070 09951 18210 Attachment Oil seal remover
159. to counter shaft front bearing 1 and press fit bearing with press and special tool NOTE When installing bearing bring it so that its groove for cir clip is in the front Special tool A 09940 54950 MANUAL TRANSMISSION TYPE 2 7A1 31 3 Select circlip that will make its thrust clearance 0 1 mm 0 0039 in or less and install it Circlip thickness specification Circlip thickness 2 05 2 10 mm 0 0807 0 0826 in 2 10 2 15 mm 0 0827 0 0846 in Special tool B 09900 06107 1 Circlip 2 Thickness gauge Input shaft bearing retainer and oil seal Install new oil seal 2 to bearing retainer 1 by using special tool as shown in the figure Apply grease to oil seal lip Grease 99000 25010 Special tool A 09913 75821 B 09924 84510 004 Oil seal installing position a 12 2 13 2 mm 0 49 0 51 in Transmission rear case 1 Check that interlock cam component 1 moves smoothly in both turning direction and sliding direction 7A1 32 MANUAL TRANSMISSION TYPE 2 2 Insert interlock cam component 1 to rear case 2 i K We y 3 Set interlock cam component 1 as shown in the figure and drive pin by using special tool Special tool A 09922 85811 4 Apply thread lock cement to thread of interlock cam plug 1 and tighten it to specification A Cement 99000 32020 Tightening torque Interlock cam plug a 19 N m 1 9 kg m 14 0 Ib
160. und 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 If the air bag system and another vehicle system both need repair SUZUKI recommends that the air bag system be repaired first to help avoid unintended air bag system activation Do not modify the steering wheel instrument panel or any other air bag system component on or around air bag system components or wiring Modifications can adversely affect air bag system performance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process remove the air bag system components air bag inflator module sensing and diagnostic module SDM seat belt pretensioner if equipped beforehand to avoid component damage or unin tended activation The circle with a slash in this manual means Don t do this or Don t let this happen Foreword This manual provides information on the unit repair service procedures for the following units Applicable Units Manual Transmission Automatic Transmission Transfer Differential e GRAND VITARA units on and after the following vehicle identification numbers VINs 252GTA03C00600001 JS3TAO3V 1 34100001 252GTA52C00600001 JS3TBO3V A 34100001 Xx JSAFTA03V00200001 JS3TB52V 34100001 JSAFTA03V30200001 JS
161. ve step 6 do it after following steps 7 and 8 7 Push gear shift shaft inward and drive out spring pin for reverse gear shift limit yoke 6 8 Pull out gear shift shaft 8 from case 1 3 Reverse gear shift limit bolt 11 Select return inner and outer spring double coil spring 12 Select guide pin 13 Select return outer spring MANUAL TRANSMISSION TYPE 1 7A 7 Gear Shift Lever Case 2WD Model 1 Using spring pin remover drive out double spring pin 10 for gear shift arm 9 2 Drive out spring pin 4 for reverse gear shift limit spring 7 3 Drive out double spring pin 2 for gear shift lever 5 4 Pull out gear shift shaft 8 a little and take out gear shift arm 9 NOTE e Case plug may come off during above work e If it is not possible to take out gear shift arm 9 in above step 4 do it after following steps 5 and 6 5 Push gear shift shaft 8 inward and drive out spring pin for reverse gear shift limit yoke 6 6 Pull out gear shift shaft 8 from case 1 3 Reverse gear shift limit bolt Transmission Unit 1 Remove 12 fastening bolts and separate rear case 3 2 Remove clutch release bearing 2 3 Remove 8 clutch housing bolts and then remove clutch housing 1 4 Remove 8 bolts and pull out input shaft bearing retainer 1 by using large size screwdrivers 2 and clean cloth 3 CAUTION When pulling out do not scratch the transmission case surface contacting w

Grand Vitara/XL-7 Transmission Factory Service Manual

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