Home

1998 Sidekick FSM - Drivetrain Manual

1. 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 MANUAL TRANSMISSION TYPE 2 7A1 17 4 Remove pin by using special tool Special tool A 09922 85811 5 Pull out interlock cam component 1 COMPONENTS INSPECTION E p REI 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 18 MANUAL TRANSMISSION TYPE 2 PAA HORS u MAIN SHAFT ASSEMBLY Check clearance a between synchronizer ring and gear key slot width b in synchronizer ring and e
2. 7F 10 DISASSEMBLING UNIT PROP 7F 3 ASSEMBLING UNIT anannnnnnnnnnnnnnnnnnnnnnnnnnnnnnne 7F 14 COMPONENT INSPECTION 7 6 TIGHTENING TORQUE SPECIFICATION 7F 18 SUB ASSEMBLY ADJUSTMENT AND REQUIRED SERVICE MATERIAL 7F 18 HEASSEMBLY aa 7F 6 SPECIAL TOOL centenis 7F 19 DIFFERENTIAL CARRIER ann 7F 6 DIFFERENTIAL 7F 6 7F 2 DIFFERENTIAL REAR GENERAL DESCRIPTION The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle It is set in the con ventional 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 8 1 Universal joint flange 9 Differential carrier assembly 15 Thrust washer 23 Bevel gear bolt 2 Bevel pinion gear set 10 Differential pinion 16 Differential side bearing 24 Bolt 3 Bevel pinion spacer 11 Differential gear 17 Bearing adjuster 25 Bolt 4 Shim 12 Pinion shaft No 1 18 Lock plate 26 Lock washer 5 Rear bearing 18 1 Differential left case 4 differential pinion type 19 Pinion shaft No
3. 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 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 Cement 99000 32020 2 Center case 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 flush 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 Cement 99000 32020 Tightening torque Rear case plate bolt a 8 N
4. 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 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 low 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 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 MANUAL TRANSMISSION TYPE 1 7A 11 UPPER CASE AND SHIFTER 1 Remove back up light swit
5. SUB ASSEMBLY REPAIR OIL PUMP 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 1 Oil pump assembly 2 Oil pump body oil seal 3 Oil pump cover O ring 5 Drive gear 7 Sealring 4 Driven gear 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 Check seal ring 2 and bushing 1 for wear and damage 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 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 0 01181 in NOTE Measure with torque converter installed 7B1 12 AUTOMATIC TRANSMISSION 4 A T 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
6. 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 Install so that opening in snap ring 1 will not align with any of 3 lugs of spring seat Do not compress spring more than necessary and do not allow it fall or tilt 400 mm 15 7 in AUTOMATIC TRANSMISSION 4 A T 7B1 55 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 NOTE To protect transmission case against damage spread cloth on stand where case contacts 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 in trans mission 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
7. 5 1 Lower valve body 6 Lower valve body gasket 11 Pin 2 Spring 7 TCC Lock up control valve plate 12 Retainer 3 Pressure relief valve ball 8 TCC Lock up control valve gasket 13 Primary regulator valve sleeve 4 Pressure relief valve retainer 9 TCC Lock up control sleeve 14 Primary regulator valve plunger 5 Lower valve body plate 10 TCC Lock up control valve 15 Primary regulator valve AUTOMATIC TRANSMISSION 4 A T 7B1 51 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 52 AUTOMATIC TRANSMISSION 4 A T 6 After removing shift solenoid valve A amp B 1 remove sole noid valve gasket low coast modulator valve spring 2 inter coast modulator valve spring 3 and 2 intermediate coast
8. 7E 8 UNIT REPAIR eerte 7E 3 DRIVE BEVEL PINION 7E 10 en ar ASSEMBLY UNIT ees 7E 13 COMPONENTS INSPECTION 7E 6 TIGHTENING TORQUE SPECIFICATION 7E 18 DIFFERENTIAL LEFT CASE 7E 6 REQUIRED SERVICE MATERIAL 7E 19 FREE AXLE HUB sect ege eee 7E 7 SPECIAL TOOL eerte 7E 19 ACTUATORS Lr EA 7E 7 SUBASSEMBLY ADJUSTMENT AND REASSEMBLY 7E 8 7E 2 DIFFERENTIAL FRONT GENERAL DESCRIPTION COMPONENT 7 1 Flange nut 8 Front bearing 15 Actuator 22 Differential right case 2 Universal joint flange 9 Shim 16 Bolt 23 Thrust washer 3 Oil seal 10 Bevel pinion gear set 17 Differential case assembly 24 Differential gear 4 Rear bearing 11 Bolt 18 Bevel gear bolt 25 Free axle hub 5 Carrier assembly 12 Lock plate 19 Differential inner air hose 26 Differential pinion 6 Bolt 18 Bearing adjuster 20 Air inlet union 27 Differential left case 7 Bevel pinion spacer 14 Differential side bearing 21 Bearing cap bolt 28 Screw 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
9. 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 Make sure to use new spacer for reinstallation 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 I 09951 18210 9 While tightening flange nut gradually with special tool and power wrench 4 10 magnification 1 set preload of pinion to specification NOTE Before taking measurement with spring balance 3 or torque wrench 4 check for smooth rotation by hand Bearing preload can be measured roughly by pinion rotating angle which is due to arm weight of flange holder installed in flange Be sure to tighten gradually and carefully till specified starting torque is obtained Turning back overtightened 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
10. Sealed bearing must not be washed Replace it with new one when required MANUAL TRANSMISSION TYPE 1 7A 9 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 57 PT inp 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 WOR RIESEN dE d 4 UR 757 C 3 Remove 3rd synchronizer ring 2 3rd gear 1 and needle D aaan xy ak E zm L bearing cuc NOTE e A 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 7A 10 MANUAL TRANSMISSION TYPE 1 ART
11. When dial gauge measuring tip extends from 0 zero position pointer turns counterclockwise Measured value may exceed 1 mm Therefore 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 Dial gauge sary shim type or Eege ment thickness 102 4 differen value o printed on T tial pinion type pinion 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
12. 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 TRANSMISSION INTERMEDIATE CASE AND FRONT CASE LOCATION OF KNOCK AND PLUG Install knock pin 1 and plug 2 sealant applied to front case as shown A Sealant 99000 31110 Section 22 Approx 0 2mm 0 079 in MANUAL TRANSMISSION TYPE 2 7A1 31 Install knock pin 2 ring pin 1 as shown in the figure A Front side B Rear side TRANSMISSION UNIT NOTE Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear 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 case 7A1 32 MANUAL TRANSMISSION TYPE 2 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 S
13. 8 Oil filler level plug 16 Transmission rear case 24 Bush MANUAL TRANSMISSION TYPE 2 7A1 5 UNIT DISASSEMBLY GEAR SHIFT LEVER CASE 1 Remove case plate 2 With case supported with soft jawed vise remove lever locating bolts 6 NOTE Use aluminum plates between vise and case to protect case against damage A 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 6 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 Magnet 4 Remove return spring low bolt 1 and return spring reverse bolt 2 5 Remove gear shift shaft inner bolt 1 plug 2 MANUAL TR
14. mounting and remounting sembly and reassembly Select a clean place free from dust and dirt for overhauling Place a rubber mat on the work bench to protect parts from damage Work gloves or shop cloth should not be used Use a nylon cloth or a paper towel When separating the case joint do not pry with a screwdriver or such but tap with a plastic hammer lightly Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during disas into it But use ATF to wash the disc resin washers and rubber parts Replace each gasket oil seal and O ring with a new one Apply ATF to sliding or rotating parts before reassembly A new disc should be soaked in ATF at least 2 hours before use PART INSPECTION AND CORRECTION TABLE 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 Part Inspect for Correction Casted part machined part Small flaw burr Remove with oil stone Deep or grooved flaw Replace part Clogged fluid passage Clean with air or wire Flaw on installing surface residual Remove with oil stone or replace lip contacts foreign material gasket part Crack Replace part Bearing Unsmooth rotation Replace Streak pitting flaw crack Rep
15. 20 5 Ib ft MANUAL TRANSMISSION TYPE 2 7A1 41 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 4 Magnet 47 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 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 7A1 42 MANUAL TRANSMISSION TYPE 2 TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening part Nem kg m Ib ft Transfer oil filler level and drain plugs 23 2 3 17 0 Transmission oil filler level and drain plugs 38 3 8 27 5 Back up light switch 45 4 5 32 5 Control lever locating bolts 17 1 7 12 5 Shift lever case plate screws 6 0 6 4 5 Gear shift lever case bolts 23 2 3 17 0 Interlock cam plug 19 1 9 14 0 Main amp counter shaft bearing plate screws 19 1 9 14 0 Reverse gear shaft bolt 18 1 8 13 5 Reverse link stay 19 1 9 14 0 Shift fork bolts 20 2 0 14 5 Locating spring screws 19 1 9 14 0 Input shaft bearing retainer bolt 17 1 7 12 5 Tra
16. Center case 2 Rear case 6 Remove circlip 1 by using screwdrivers and hammer then pull out speedometer drive gear 3 and steel ball 2 Output rear shaft 7 Remove circlip for bearing and pull out bearing No 2 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 sprocket 6 with drive chain 7 and synchronizer plate 1 NOTE Watch out 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 Remove counter gear 2 shaft 3 together with needle bearings spacer washers 4 and steel balls 5 from case NOTE 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 13 Remove O ring from counter gear shaft 2 and then remove friction ring 3 from sha
17. 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 Necessary Dial gauge Measurement shim thick 94 measured printed on ness f value 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 sec tion 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 Make sure to use new spacer for reinstallation 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 to oil seal
18. is at reverse position 11 After confirming switch function remove gear shift lever case 2 Ohmmeter MANUAL TRANSMISSION TYPE 1 7A 29 12 Connect transfer assembly to transmission 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 5th switch and back up light switch 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 AWD model Extension case 2WD model 7A 30 MANUAL TRANSMISSION TYPE 1 TIGHTENING TORQUE SPECIFICATION Fastening part Tightening torque Nem kg m Ib ft Oil level filler and drain plugs 23 2 3 17 0 Back up light and 4WD switches 20 2 0 14 5 Control lever locating bolts 17 1 7 12 5 Reverse gear shift limit
19. 0 0039 in or less and install it Circlip thickness specification ID mark Circlip thickness 1 2 05 2 10 mm 0 0807 0 0826 2 10 2 15 mm 0 0827 0 0846 2 15 2 20 mm 0 0847 0 0866 2 20 2 25 mm 0 0867 0 0885 in 2 25 2 30 mm 0 0886 0 0905 in 2 30 2 35 mm 0 0906 0 0925 in A Q N Special tool B 09900 06107 1 Circlip 2 Thickness gauge MANUAL TRANSMISSION TYPE 2 7A1 29 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 TRANSIMISSION REAR CASE 1 Check that interlock cam component 1 moves smoothly in both turning direction and sliding direction 2 Insert interlock cam component 1 to rear case 2 3 Set interlock cam component 1 as shown in the figure and drive pin by using special tool Special tool A 09922 85811 7A1 30 MANUAL TRANSMISSION TYPE 2 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 ft
20. 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 Special tool 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 hole at the extreme right And then remove O rings from pistons INSPECTION Direct Clutch Piston Return Spring Measure free length Standard free length of direct clutch piston return spring 15 13 mm 0 595 in Direct Clutch Piston Shake piston to check that ball is not stuck Apply air pressure and check that there is no leakage ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points Always use new O ring and apply A T fluid before installa tion Do no
21. 1 brake backing plate 2 brake disc 3 brake plate 4 cushion brake plate 5 in that order zm d Then remove planetary ring gear thrust bearing race and gt 4 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 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 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 When installing rear seal ring use care not to open it too wide Apply A T fluid to O ring disc etc before installing them Opening of retaining brake front ring 2 and projection 1 of O D case should be matched When installing each component refer to the first figure of OVER DRIVE CASE SIDE in this section 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
22. 1 Valve body ball 2 2 Needle roller Lower valve body assembly Bypass valve Valve body ball Check ball Om ES o HM Primary regulator valve sleeve retainer Locating pin 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 Deo pe a 09000 8 o 3 AUTOMATIC TRANSMISSION 4 A T 7B1 41 2 Place new upper valve body gasket on lower valve body assembly 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 indicated 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 bol
23. 1 with special tool and press Special tool B 09925 18011 2 5th gear 3 Ring 4 Sleeve and hub assembly 12 Fit small circlip 7A 22 MANUAL TRANSMISSION TYPE 1 I 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 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 MANUAL TRANSMISSION TYPE 1 7A 23 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
24. 2 27 Bolt 6 Front bearing 13 2 Differential left case 2 differential pinion type 20 Pinion joint 28 Differential case bolt 7 Oil seal 14 1 Differential right case 4 differential pinion type 21 Spring washer 8 Flange nut 14 2 Differential right case 2 differential pinion type 22 Washer 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 Differential carrier Drive bevel gear assembly Differential case ZS oz 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 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 pin ion gear and pinion shaft a Remove bevel gear by removing its b
25. 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 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
26. 7B1 33 When installing snap ring do not align lug 1 of retainer with opening in snap ring 2 When installing brake discs brake plates and clutch backing plate refer to the first figure of CENTER SUPPORT in this section Install clutch backing plate with its chamfered side facing brake disc 1 Clutch disc facing side 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 18 Bearing race 1 Inner shaft 7 Front planetary gear 13 Retaining ring 19 Output shaft assembly 2 Retaining ring 8 Reverse brake plate 14 Rear planetary gear 20 Key 3 Reverse brake reaction plate 9 Reverse brake disc 15 Planetary sun gear 21 Seal ring 4 Retaining ring 10 Reverse brake backing plate 16 Bearing 22 Brake applying tube 5 One way clutch 11 Washer 17 Rear planetary ring gear AUTOMATIC TRANSMISSION 4 A T 7B1 35 DISASSEMBLY 1 Remove front planetary gear assembly 1 from output shaft a
27. AND SHIFTER 7A 11 TRANSMISSION UNIT 7A 27 COMPONENT INSPECTION 7A 11 TIGHTENING TORQUE SPECIFICATION 7A 30 COUNTER SHAFT AND MAIN SHAFT REQUIRED SERVICE MATERIAL 7A 30 INNER PARTS 11 SPECIAL 4 4 00000 31 LOW AND REVERSE SCISSORS GEAR ASSEMBLIES IF EQUIPPED 7A 13 7A 2 MANUAL TRANSMISSION TYPE 1 COMPONENTS GENERAL DESCRIPTION ouogmromc 10 11 12 13 Input shaft Needle bearing Input shaft bearing C ring Circlip Oil seal Main shaft Main shaft bearing C ring Bearing washer Rear bearing Circlip Ball 14 15 16 17 18 19 20 21 22 23 24 25 26 Circlip Oil seal Low gear Needle bearing Low gear bush 2nd gear Needle bearing 3rd gear Needle bearing 5th gear Needle bearing 5th gear washer Counter shaft 27 28 29 30 31 32 33 34 35 36 37 38 39 Front bearing Circlip Center bearing Bush Rear bearing Circlip Bearing plate Bolt 5th gear Counter shaft plug Low speed hub High speed hub Reverse hub 40 41 42 43 44 45 46 4T 48 49 50 51 52 Low speed sleeve High speed sleeve Reverse sleeve Low speed ring High speed ring Low speed spring High speed spring Synchronizer key 5th synchronizer key Reverse gear Needle bearing Bush Reverse gear 53 54 55 56 57
28. Transfer input gear 6 4WD switch 11 Synchronizer inner ring 16 Transfer counter gear 2 Reduction shift sleeve 7 Transfer gear shift control lever 12 Center cone 17 Transfer counter shaft 3 Output low gear 8 Sliding yoke 13 Synchronizer outer ring 18 Ball 4 Front drive clutch sleeve 9 Output rear shaft 14 Drive chain 19 Synchronizer plate 5 Drive sprocket 10 Speedometer driven gear 15 Output front shaft TRANSFER 4WD 7D 3 Input gear Needle bearing Input gear bearing Input bearing circlip Input gear circlip Oil seal Counter gear Counter shaft Spacer Needle bearing O ring Washer ball Washer 14 15 16 17 18 19 20 21 22 23 24 25 26 Plate Bolt Output rear shaft Washer ball Rear shaft No 1 bearing Washer ball Rear shaft No 2 bearing Adjusting shim Output low gear Needle bearing Reduction clutch hub Circlip Reduction shift sleeve 27 28 29 30 31 32 33 34 35 36 37 38 39 Front drive clutch hub Front drive clutch sleeve Drive sprocket Needle bearing Sprocket bush Drive chain Output front shaft Bearing Speedometer drive gear Circlip Speedometer driven gear Spring Speed sensor 40 41 42 43 44 45 46 4T 48 49 51 52 O ring Clip Bolt Needle bearing Oil seal Friction ring Synchronizer outer ring Center cone Synchronizer inner ring Synchronizer plate
29. adjusting shim and position pinion farther from gear cen ter 2 Adjust drive bevel gear backlash to specification 4 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 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 Tightening torque Fastening part Nem kg m Ib ft Air inlet union 13 1 3 9 5 Actuator bracket bolts 12 1 2 9 0 Bevel gear bolts 85 8 5 61 5 Bearing cap bolts 60 6 0 43 5 Lock plate bolts 13 1 3 9 5 Front differential carrier bolts 23 2 3 17 0 REQUIRED SERVICE MATERIAL DIFFERENTIAL FRONT 7E 19 Material Recommended SUZUKI
30. and right outer races are not interchangeable Install case assembly in carrier Install side bearing adjusters on their respective carrier making sure adjuster are threaded properly QD lt 4 Align match marks 1 on cap and carrier Screw in 2 side 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 Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth 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 Measure at least 4 points on drive bevel gear periph ery 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 ch
31. and try ing to turn the race in both directions The inner race should turn freely clockwise but be heavy to turn counterclockwise NOTE Converter placed with its flange upright does not fit for this inspection For proper checking position converter with its flange horizontal 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 FOL LOWING CONDITIONS 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 PRECAUTIONS As the automatic transmission consists of high precision components the following cautions should be strictly UNIT REPAIR observed when handling its parts in disassembly and reassembly Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during dis
32. 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 Er gt I lt 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 5 Differential carrier g Differential carrier mounting distance a b c 6 Front bearing Bevel pinion mounting distance Marked in shaft in mm 7 Spacer f Shim size for mounting distance adjustment d e 8 Bevel pinion 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 This installation requires universal joint flange not equipped with groove on flange periphery This insta
33. clutch ring of planetary sun gear is held brake valve gets off center support and that will make it impossible to align fluid holes with bolt holes KD B AUTOMATIC TRANSMISSION 4 A T 7B1 57 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 NOTE Ends of splines in direct clutch cylinder and planetary sun gear should come almost in match 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 58 AUTOMATIC TRANSMISSION 4 A T 15 When clutch disc and plate have been replaced check height difference between forward clutch input shaft an
34. 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 IN 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 Check companion flange for wear or damage Check bearings for wear or discoloration Check differential carrier for cracks Check drive bevel pinion and bevel gear for wear or cracks Check side gears pinion gears and pinion shaft for wear or damage Check side gear spline for wear or damage DIFFERENTIAL LEFT CASE Check clutch for smooth movement by push
35. lip Special tool G 09951 18210 A Grease 99000 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 Before taking measurement with spring balance 3 or torque wrench 4 check for smooth rotation by hand 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 Be sure to tighten gradually and carefully till specified starting torque is obtained Turning back overtightened 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 A
36. 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 bearing No 1 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 Bearing No 1 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 toward bearing Special tool D 09925 18011 E 09940 53111 F 09951 26010 12 Install fork to corresponding shift shaft Spring pin Reduction fork Reduction shift shaft Circlip Washer Front drive shift fork Spring Front drive shift shaft TRANSFER 4WD 7D 15 13 Fit sleeve to front drive clutch hub 1 place 3 synchronizer keys 4 if equipped in it and then set synchronizer springs 2 3 if equipped
37. 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 primary regulator valve plunger 2 primary regulator valve spring 3 and primary regulator valve 4 AUTOMATIC TRANSMISSION 4 A T 7B1 53 ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points 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 Pressure relief valve spring 13 14 mm 0 517 in 32 14 mm 1 265 in TCC Lock up control valve 11 40 mm 0 449 in 32 60 mm 1 283 in spring Valve damping spring 4 95 mm 0 195 in 20 00 mm 0 787 in Low coast modulator valve spring 10 00 mm 0 394 in 35 43 mm 1 395 in Inter coast modulator valve 9 04 mm 0 356 in 27 26 mm 1 073 in spring G16 and J20 engines G16
38. oil seal by hitting Use drive punch for hammering 23 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 24 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 25 Remove oil seal from rear case 1 And then using same special tools and press as in step 24 remove needle bear ing 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 TRANSFER 4WD 7D 9 26 Using special tool remove circlip 3 of input gear 1 from front case 2 NOTE Be sure to use right tool to ensure proper work Special tool H 09900 06108 27 Using plastic hammer drive input gear 2 out of front case 1 NOTE Becareful not to damage oil seal 3 by hitting If removed do not reuse oil seal 28 Remove circlip 2 of input gear 1 by using special tool Special tool I 09900 06107 29 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 30 With spring 3 on front drive fork shaft 4 c
39. product Part Number Use Thread lock cement THREAD LOCK CEMENT SUPER 1333B 99000 32020 Bevel gear bolts Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips Sealant SUZUKI BOND NO 1215 99000 31110 Front differential drain and filler plug Mating surface of differential housing Air inlet union SPECIAL TOOL 09900 20606 Dial gauge 09900 20701 Magnetic stand 09913 61510 Bearing puller 09913 75510 Bearing installer 09913 85230 Bearing removing jig 09922 66020 Flange holder 09922 75222 Preload adjuster 09924 74510 Installer attachment 09925 18011 Bearing installer 09926 68310 Bearing installer 09926 78311 Bevel pinion mounting dummy 09930 40113 Rotor holder 7E 20 DIFFERENTIAL FRONT 09930 40120 Attachment Q 5 09927 66010 J23082 01 Oil pump aligner 09944 66020 Bearing installer 09944 76010 Differential carrier holder 09951 16060 Lower arm bush remover 09951 18210 Oil seal remover amp installer No 2 09913 65135 Bearing puller 09918 18110 Air pressure regulator DIFFERENTIAL REAR 7F 1 SECTION 7F DIFFERENTIAL REAR CONTENTS GENERAL 7F 2 DIFFERENTIAL SIDE BEARING 7F 9 UNIT 0 4 7F 3 DRIVE BEVEL PINION
40. 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 1 Over drive case 2 Clutch cylinder 14 Remove oil pan 1 NOTE Hold oil pan with oil pan side down to prevent foreign material in oil pan from entering valve body f iron powder is found it is possible that bearing gear 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 1 400 mm 15 7 in 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 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 in
41. remove cut back plug cut back valve and cut back valve spring 3 Remove one cover bolt on front valve end cover 1 and loosen the other to move cover as shown in figure Remove secondary regulator valve sub assembly and secondary reg ulator valve spring Then remove remaining loose cover bolt to remove front valve end cover 1 WARNING When moving cover be sure to hold valve with finger to prevent secondary regulator valve sub assembly from jumping out 4 Remove throttle cam bolt 1 and then remove throttle valve cam 2 throttle cam return spring 4 and cam spacer 3 AUTOMATIC TRANSMISSION 4 A T 7B1 45 5 With throttle valve held as shown in the figure remove locat ing pin 1 with magnet 2 and then remove throttle valve and throttle valve primary spring 6 Remove throttle valve and then remove throttle valve sec ondary spring and throttle valve compensating ring s 1 NOTE Write down how many throttle valve compensating rings 1 there were for throttle pressure varies with number of them ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points 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 lengt
42. 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 A J20 engine 4 O ring 9 Clutch disc B G16 and H25 engines 5 Retaining ring 10 Froward clutch hub 1 Input shaft 6 Bearing race 11 Direct clutch input hub 2 Piston 7 Bearing 3 Return spring 8 Clutch plate 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 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
43. shaft with press 2 and special tool Special tool B 09927 08220 14 Select circlip 1 that will make clearance in circlip groove O 1 mm 0 0039 in or less Circlip thickness specification Circlipthickness 2 80 2 85 mm 0 1103 0 1122 in 2 85 2 90 mm 0 1122 0 1141 in 2 90 2 95 mm 0 1142 0 1161 in 2 95 3 00 mm 0 1162 0 1181 in 3 00 3 05 mm 0 1182 0 1200 in 3 05 3 10 mm 0 1201 0 1220 in 3 10 3 15 mm 0 1221 0 1240 in w gt 2 Thickness gauge 15 Fix with circlip 1 as shown in the figure and check that counter 5th gear turns lightly MANUAL TRANSMISSION TYPE 2 7A1 35 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 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 Support
44. so as to protect retainer of throttle cable 7B1 62 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 spring specification G16 engine Used for Piston outer diameter a Spring free length b Direct clutch accumulator 2 31 80 31 85 mm 1 252 1 254 in 31 80 31 85 mm Forward clutch accumulator 1 1 252 1 254 in Second brake accumulator 3 34 80 34 85 mm 1 370 1 372 in Upper spring 61 21 mm 2 410 in Lower spring Upper spring 64 68 mm 2 546 in Lower spring Upper spring 55 18 mm 2 172 in Lower spring 35 13 mm 1 383 in Accumulator piston and spring specification J20 engine Used for Piston outer diameter a Spring free length b Direct clutch accumulator 2 31 80 31 85 mm 1 252 1 254 in Forward clutch accumulator 1 31 80 31 85 mm 1 252 1 254 in Second brake accumulator 3 34 80 34 85 mm 1 370 1 372 in Upper spring 59 82 mm 2 355 in Lower spring Upper spring 64 68 mm 2 546 in Lower spring Upper spring 55 18 mm 2 172 in Lower spring 35 13 mm 1 383 in Accumulator piston and spring specification
45. 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 6 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 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 Apply thread lock cement A to control lever locating bolts 2 when replaced 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 MANUAL TRANSMISSION TYPE 1 7A 19 SUB ASSEMBLY MAIN SHAFT 1 2 3 4 3 5 10 12 13 3 14 15 16
46. 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 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 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 h
47. 0 0039 in ASSEMBLY Assemble each component by reversing removal procedure and noting following points Before installing inner gear and outer gear to pump body apply A T fluid to them 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 When installing O ring and oil seal apply enough A T fluid to them and fit them securely in groove After installation check that inner gear turns smoothly by making use of torque converter When installing seal ring it should not be opened more than necessary Fit claws of seal ring securely AUTOMATIC TRANSMISSION 4 A T 7B1 13 OVERDRIVE PLANETARY GEAR SIDE 5 1 14 13 11 3 2 L 42 22 5 4 1 Bearing 5 O ring 9 Clutch backing plate 13 One way clutch 2 Race 6 Return spring 10 Clutch disc 14 Thrust washer 3 Clutch cylinder 7 Snapring 11 Retaining ring 15 O D planetary gear 4 Clutch piston 8 Cushion clutch plate 12 Brake hub 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 as
48. 00 20701 Magnetic stand 09913 61510 Bearing puller 09913 65135 Bearing puller 09922 77250 Attachment 09913 75510 Bearing installer 09913 85230 Bearing removing jig 09922 66020 Flange holder 09922 75222 Preload adjuster 09922 85811 Spring pin remover 09924 74510 Installer attachment 09925 18011 Bearing installer ah 09926 68310 Bearing installer EN NY 09926 78311 Bevel pinion mounting dummy Q E 09927 66010 J 23082 01 Oil pump aligner ty 09928 06010 002 Differential torque checking tool 7F 20 DIFFERENTIAL REAR 09930 40113 Rotor holder 09930 40120 Attachment 09944 66020 Bearing installer 09951 16060 Lower arm bush remover 09951 16070 Attachment 09951 18210 Oil seal remover amp installer No 2 09951 46010 Drive shaft oil seal installer Prepared by SUZUKI MOTOR CORPORATION Overseas Service Department 1st Ed Jan 1998 2nd Ed May 2000 Printed in Japan Printing May 2000 2138
49. 063 in Service limit 24 0 mm 0 945 in REAR CASE e f oil seal 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 portion Grease A 99000 25010 Special tool A 09913 75510 1 Oil seal 2 Rear case MANUAL TRANSMISSION TYPE 1 7A 15 If oil leakage exists at counter shaft end plug replace it Special tool B 09913 75520 1 Rear case 2 Counter shaft end plug 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 nec essary carefully by using reamer oilstone and the like wash it thoroughly and reassemble them Items to be checked are Shift shaft should go into case smoothly 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 Cut off portion 5 in shift shaft should face downward when shift shaft 1 is installed Usecare for installing direction of shift limit spring 4 Shift arm should be installed at the same time 2 Shiftlever 3 Shift limit yoke 3 Drive in spring pin single sho
50. 17 l m PR VL qur m e ELS FLG EP Pen IOUT E oe NO EF gl EM KIN KJE Dp ale A rE E f AR 1 CU 0 To a U LT 6 7 8 7 9 10 11 1 Input shaft bearing 7 Synchronizer low speed ring 18 Synchronizer reverse sleeve and hub assembly 2 Input shaft 8 Synchronizer 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 Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear 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 kale A B 7A 20 MANUAL TRANSMISSION TYPE 1 2 Install needle bearing 2 2nd gear 3 and 2nd synchronize
51. 3111 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 ID mark Circlip thickness C 1 1 75 1 80 mm 0 0689 0 0708 in D 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 1 95 2 00 mm 0 0768 0 0787 in F 2 00 2 05 mm 0 0788 0 0807 in F 1 2 05 2 10 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 26 MANUAL TRANSMISSION TYPE 2 FORWARD FORWARD 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 with 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 other in order to apply spring tension equally to each key NOTE Before installing hub 3 sleeve 4
52. 5 18011 09927 08210 09944 66010 09951 16080 Bearing installer Shaft remover Wheel hub knuckle oil Bearing installer seal installer 7A 32 MANUAL TRANSMISSION TYPE 1 MANUAL TRANSMISSION TYPE 2 7A1 1 SECTION 7A1 MANUAL TRANSMISSION TYPE 2 TYPE 2 For H25 RF Engines 7A1 CONTENTS GENERAL DESCHIEPTION eee 7A1 2 UNIT ASSEMELN tette 7A1 22 bec 7 1 2 GEAR SHIFT LEVER 7A1 22 UNIT DISASSEMBLY ener 7A1 5 SUB ASSENIBLY 3 tries 7A1 23 GEAR SHIFT LEVER 7A1 5 INPUT SHAFT ASSEMBLY 7A1 23 TRANSMISSION UNI 7A1 5 MAIN SHAFT 7A1 24 SUB ASSEMBLY is cain eva 7A1 14 COUNTER SHAFT AND REVERSE INPUT SHAFT ASSEMBLY Ee S 7A1 14 IDLE GEAR TTT 7A1 28 MAIN SHAFT ASSEMBLY 7A1 14 INPUT SHAFT BEARING RETAINER COUNTER SHAFT amp REVERSE IDLE AND OIL SEAL 7A1 29 eee 7A1 15 TRANSIMISSION REAR CASE 7A1 29 INPUT SHAFT BEARING RETAINER IBAN OMISSION INTERMED TE ANDOILSEAL een 7A1 16 CASE AND FRONT CASE LOCATION TRANSMISSION REAR CASE MENTO DS 7A1 16 OF KNOCK AND PLUG anannsnnnnnsnnnnnnnnne 7A1 30 TRANSMISSION UNIT COMPONENTS INSPECTION 7A1 17 222 SUB ASSEMBLY c 7A1 17 QU 7 1 ee Ar REQUIRED SERVICE MATERIAL 7A1 42 MAI
53. 5 Ib ft MANUAL TRANSMISSION TYPE 2 7A1 23 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 Apply thread lock cement C to control lever locating bolts 1 when retightening Be sure to apply sealant to mating surface of gear shift lever case 2 for its final installation 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 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 will make thrust clearance of bearing 0 1 mm 0 0039 in or less and install it Circlip thickness specification ID mark Circlip thickness 0 2 05 2 10 mm 0 0807 0 0826 in 2 10 2 15 0 0827 0 0846 in 2 15 2 20 0 0847 0 0866 in 2 20 2 25 0 0867 0 0885 in 2 25 2 30 0 0886 0 0905 in 2 30 2 35 0 0906 0 0925 in 0 A O N 7A1 24 MANUAL TRANSMISSION TYPE 2 FORWARD 18 9 mm FORWARD 074m gt FORWARD 3 Apply grease to bearing r
54. 58 59 60 61 62 63 Reverse idle gear Needle bearing Idie gear shaft Thrust washer Bolt Washer Friction gear Friction gear retainer Friction gear spring Pin Circlip MANUAL TRANSMISSION TYPE 1 7A 3 90 ICON Ur EO qo Lower gear shift fork High gear shift fork 5th reverse gear shift fork Low gear shift shaft High gear shift shaft 5th reverse gear shift shaft Plug Gasket 10 11 12 13 14 15 16 Locating spring Locating ball Spring pin Roller Gear shift lever case Case seat Bolt Spring 17 18 19 20 21 22 23 24 Select guide pin Spring inner Reverse gear shift limit bolt Breather hose Gear shift shaft Case plug Gear shift lever Reverse gear shift limit spring 25 26 27 28 29 Reverse gear shift limit yoke Gear shift arm Gear control lever bush Case plate Plug 7A 4 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 spr
55. 8 1 2193 in 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 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 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 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 1 3007 in MANUAL TRANSMISSION TYPE 2 7A1 21 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 Cil 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 Check clearance between reverse idle gear 2 and shoe 1 of reverse gear shift link If clearan
56. A 25 NOTE 1 2 2 Reverse gear shift fork spring pin is different from other 5 spring pins 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 iu P 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 then put in inter lock ball 3 NOTE Note that high speed gear shift shaft 2 can t be inserted unless reverse gear shift shaft 1 is placed at neutral position 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 7A 26 MANUAL TRANSMISSION TYPE 1 HS 4 Confirm that interlock system operates properly by checking the following When shifted to low position or 2nd position shifting of 3rd 4th speed or 5th Re
57. ANSMISSION TYPE 2 7A1 7 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 Special tool A 09912 34510 8 Remove input shaft bearing retainer 1 and gasket 7A1 8 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 9 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
58. H25 engine Used for Piston outer diameter a Spring free length b Direct clutch accumulator 2 31 80 31 85 mm 1 252 1 254 in Upper spring 43 56 mm 1 715 in Lower spring 30 80 mm 1 213 in Forward clutch accumulator 1 31 80 31 85 mm 1 252 1 254 in Upper spring 64 68 mm 2 546 in Lower spring Second brake accumulator 3 34 80 34 85 mm 1 370 1 372 in Upper spring 58 80 mm 2 135 in Lower spring 35 13 mm 1 383 in AUTOMATIC TRANSMISSION 4 A T 7B1 63 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 Valve body bolt nominal length a 25 mm 0 98 in b 30 mm 1 18 in c 47 mm 1 85 in 60 mm 2 36 in 37 Install new gaskets oil screen spacer and oil screen Tightening torque Oil screen bolt 5 5 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 transmiss
59. 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 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 ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing s
60. N SHAFT ASSEMBLY on 7A1 18 SPECIAL TOOL 7A1 43 COUNTER SHAFT AND REVERSE IDLE GEAR iii nre eite 7A1 20 7A1 2 MANUAL TRANSMISSION TYPE 2 GENERAL DESCRIPTION COMPONENTS e ES 6 i EEE ER ir LJ ia VC SE Hi m m di LU ve Q f 1 H d 9 emm SH d ck L ler M a ul Eu 221 6 1 Input shaft 6 Main shaft 2nd gear 11 2 Clutch release bearing 7 Main shaft low gear 12 3 Clutch release fork 8 Front case 13 4 Clutch operating cylinder 9 Main shaft reverse gear 14 5 Main shaft 3rd gear 10 Gear shift inner shaft 15 Main shaft 5th gear Gear shift lever case Gear shift shaft Main shaft Rear case 16 Counter shaft 5th gear 17 Counter shaft 18 Clutch housing MANUAL TRANSMISSION TYPE 2 7A1 3 bbe 5 9 44 4 45 47 O 46 45 6 4 d 49 45 Ua I 46 50 4 47 49 Co 0 47 O 47 47 0 8 46 54 aar se QPR cs ien 0 BEN gs moo mL Input shaft Input shaft bearing Input shaft roller Circlip C ring Synchronizer ring Synchronizer spring Synchronizer key High speed hub High speed sleeve 3rd gear Needle bearing Main shaft 14 15 16 17 18 19 20 21 22 23 24 25 26 2nd gear Low speed hub Low sp
61. Synchronizer spring type without key Synchronizer spring type with key Synchronizer key type with key 7D 4 TRANSFER 4WD UNIT REPAIR DISASSEMBLY 1 Remove 4WD switch 3 and take out steel ball 2 Remove 5 bolts and then remove gear shift lever case 4 1 Front case 2 Center case 5 Rearcase removing bolt of select return system take out spring 4 steel ball 5 and pin 6 For transfer for TYPE 2 manual transmission remove select return spring bolt 8 and then return spring 9 A 8 3 For transfer for A T and TYPE 1 manual transmission after lt gt A For transfer for A T and TYPE 1 manual transmission B For transfer for TYPE 2 manual transmission 1 Rearcase Select return spring bolt Washer aluminum Reduction shift yoke 4 hammering special tool drive spring pin out of reduction shift yoke NOTE Pin may drop into case when driven out Therefore take it out when case is disassembled After spring pin is removed yoke may be either taken out Special tool A 09922 85811 4 tn Occ Sr ee ed TRANSFER 4WD 7D 5 5 Remove 15 rear case bolts and then separate case by using special tool NOTE To separate case use special tool at 4 points in turn and make opening wider evenly Special tool B 09912 34510 1
62. When installing note that front drive clutch hub 1 and sleeve 2 have specific installing direction NOTE Make sure that bent end of synchronizer spring is inserted into hole if equipped A Jk A Thick Front side B Thin Rear side C Oil groove Rear side 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 loosely install bolt 1 2 Washer 6 Shiftfork 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 5 4 as shown in figure install them together with chain 3 to out j 2 put rear shaft 1 7D 16 TRANSFER 4WD NEN BERN 16 Install needle bearing 3 and bush 4 to sprocket 2 Also install steel ball 1 using care not to drop it NOTE Point mark on output rear shaft between positions of bearing No 2 and speedometer drive gear indicates steel ball location in the front Point mark on bush flange also means position where steel ball is met 17 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 18 Using special tool press fit bearing No 2 1 into output rear shaft It is necessa
63. YPE 2 AUTOMATIC TRANSMISSION 4 A T 7B1 1 SECTION 7B1 AUTOMATIC TRANSMISSION 4 A T 7B1 CONTENTS GENERAL DESCRIPTION 7B1 2 OVERDRIVE CASE SIDE 7B1 17 TORQUE CONVERTER DIAGNOSIS 7B1 3 FORWARD CLUTCH c 7B1 20 STATOR ASSEMBLY FREEWHEELS 7B1 3 DIRECT CLUTCH nn 7B1 24 STATOR ASSEMBLY REMAINS CENTER SUPPORT ene 7B1 28 LOCKED UP 7 1 3 PLANETARY GEARS AND OUTPUT DO NOT REPLACE CONVERTER FOR ee LA DEEN 7B1 34 FOLLOWING CONDITIONS 7B1 3 aE 0 5 UNIT REPAIR cnn 7B1 4 Sr Bid PRECAUTIONS ee 7B1 4 UNIT ASSEMBLY 7B1 54 PART INSPECTION AND CORRECTION BEARING AND RAGE INSTALLATION UNIES EE e DIAGRAM ee 7B1 66 SUB ASSEMBLY REPAIR ten 7B1 10 TIGHTENING TORQUE SPECIFICATION 7B1 67 OIL PUMP err 7B1 10 REQUIRED SERVICE MATERIAL 7B1 67 OVERDRIVE PLANETARY SPECIAL TOOL 7B1 68 GEAR SIDE 7B1 13 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 b
64. ach 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 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 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 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 Measuring portion Standard A 37 984 38 000 mm 1 4955 1 4960 in B 34 984 35 000 mm 1 3774 1 3779 in C 4 80 5 20 mm 0 1840 0 2047 in D 38 985 39 000 mm 1 5348 1 5354 E 3 955 4 195 mm 0 1558 0 1651 in MANUAL TRANSMISSION TYPE 2 7A1 19 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 m
65. aft 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 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 61 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
66. 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 Shake piston to check that ball is not stuck Blow low pressure air to check ball section for leakage AUTOMATIC TRANSMISSION 4 A T 7B1 23 Forward Clutch Piston Return Spring 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 When installing return spring 2 be careful so that return spring 2 will not fall or tilt 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 pisto
67. and J20 engines 10 00 mm 0 394 in 25 60 mm 1 008 in H25 engine H25 engine Ball valve spring 13 14 mm 0 517 in 32 14 mm 1 265 in Bypass valve spring 13 82 mm 0 544 in 28 90 mm 1 138 in Primary regulator valve spring 13 62 mm 0 536 in 50 28 mm 1 980 in Install primary regulator valve sleeve so that its tip is posi tioned as it was before disassembly Use new TCC lock up control valve gasket solenoid gas ket and lower valve body plate gasket 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 Solenoid valve No 1 Shift solenoid valve Low coast modulator valve spring Inter coast modulator valve spring Intermediate coast modulator valve ak oD Low coast modulator 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 2 O ring 7B1 54 AUTOMATIC TRANSMISSION 4 A T 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 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
68. ation Tightening torque Gear shift lever case bolt j 13 N m 1 3 kg m 9 5 Ib ft Select return pin Ball Select return spring Washer ob 46 Install gear shift control lever temporarily and check to make sure that it shifts to each shift position smoothly Also check shaft for rotation 47 Confirm 4WD switch 2 has turned ON at 4WD position 4H and 4L by using ohmmeter 1 Pull aL TRANSFER 4WD 70 23 48 Confirm 4WD LOW switch has turned ON at 4WD LOW and Neutral position 49 Upon completion of above checks remove shift control lever TIGHTENING TORQUE SPECIFICATION i Tightening torque Fastening part Nem kg m Ib ft Center case gutter bolt 8 0 8 5 5 Rear case plate bolt 8 0 8 5 5 Front case bolts 23 2 3 17 0 Counter shaft plate bolt 23 2 3 17 0 Rear case bolts 23 2 3 17 0 Locating spring bolts 26 2 6 19 0 4WD switch and 4WD LOW switch 20 2 0 15 5 Select return spring bolt For A T and TYPE 1 M T 35 3 5 25 5 Select return spring bolt For TYPE 2 M T 5 5 0 55 4 0 Gear shift lever case bolt 13 1 3 9 5 Control lever locating bolts 17 1 7 12 5 Synchronizer plate screws 10 1 0 7 5 REQUIRED SERVICE MATERIAL Material Recommended SUZUKI product Part Number Use Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips and O rings Splines of propeller shaft Select r
69. bolt 23 2 3 17 0 Select return spring bolts 35 3 5 25 5 Shift lever case plate screws 9 0 9 6 5 Gear shift case bolts 13 1 3 9 5 Center bearing plate bolts 6 0 6 4 0 Reverse idle gear shaft bolt 23 2 3 17 0 Locating spring bolts 28 2 8 20 0 Upper case bolts 23 2 3 17 0 Input shaft retainer bolts 23 2 3 17 0 Clutch housing bolts 50 5 0 36 5 Rear case bolts 23 2 3 17 0 Transfer to transmission bolts 23 2 3 17 0 REQUIRED SERVICE MATERIAL Recommended SUZUKI product Material me Part number Use SUZUKI SUPER GREASE A 99000 25010 Lithium grease Oil seal lips Select return system 99000 32020 Thread lock cement THREAD LOCK CEMENT SUPER 1333B Shift control lever locating bolts Reverse gear shift limit bolt Counter shaft bearing plate bolts Sealant SUZUKI BOND No 1215 99000 31110 Oil Drain and level filler plugs Mating surface of gear shift lever case 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 MANUAL TRANSMISSION TYPE 1 7A 31 SPECIAL TOOL 09912 34510 09913 60910 09913 61510 09913 75510 Case separator Bearing Gear puller Bearing puller O D 70 5 mm Bearing installer SA 09913 75520 09913 80112 09913 84510 09922 85811 O D 60 5 mm Bearing installer Bearing installer Spring pin remover Bearing installer O 0992
70. 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 Pinion 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 CH Ca SA 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 m 1 8 Ib ft 1 Torque wrench 2 Differential case assembly 3 Aluminum plate 4 Vise FOR 4 DIFFERENTIAL PINION TYPE 1 After ap
71. ce 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 22 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 Cut off portion 3 in shift shaft 1 should face down ward when shift shaft 1 is installed 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 A Sealant 99000 31110 3 Inner spring pin 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
72. ch 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 Check tooth surface of gear and rotation of bearing and replace with new one if necessary As long as no abnormal condition such as noise exists before removal replacement is unnecessary 7A 12 MANUAL TRANSMISSION TYPE 1 Inspect needle bearings and 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 Main shaft Low gear bush identical Reverse gear bush identical Input shaft needle bearing gear needle bearing 2nd gear needle bearing identical Low gear needle bearing identical Reverse gear nee
73. ck 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 6 Install release bearing 7A 28 MANUAL TRANSMISSION TYPE 1 7 Clean mating 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 Clutch housing Bolt Clutch release bearing Bolt Rear case aR oD 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 Back up light switch 1 should conduct when gear shift con trol lever 3
74. ct 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 OVERSEAS SERVICE DEPARTMENT COPYRIGHT SUZUKI MOTOR CORPORATION 2000 TABLE OF CONTENTS Mannual Transmission Type 1 Mannual Transmission Type 2 TRANSMISSION CLUTCH AND Automatic Transmission DIFFERENTIAL Transfer 7D Differential Front Differential Rear MANUAL TRANSMISSION TYPE 1 7A 1 SECTION 7A MANUAL TRANSMISSION TYPE 1 TYPE 1 For G16 J20 Engines CONTENTS GENERAL DESCRIPTION 7A 2 UPPER CASE AND SHIFTER 7A 14 COMPONENTS eee 7A 2 REAR CASEL 7A 14 UNIT DISASSEMBLY rre 7A 4 UNIT ASSEMBLY eene 7A 15 GEAR SHIFT LEVER CASE 4WD GEAR SHIFT LEVER CASE 4WD MODEL ee AE te 7A 4 MODEL ass een 7A 15 GEAR SHIFT LEVER CASE 2WD GEAR SHIFT LEVER CASE 2WD MODEL ae 7A 5 MODEL esse 7A 17 TRANSMISSION 7A 5 SUB ASSEMBLY 7A 19 SUB ASSEMBLY nn 7A 8 MAIN SHAFT use 7A 19 INPUT SHAFT EE 7A 8 COUNTER 7A 22 MAIN SHAFT 7A 9 UPPER CASE AND SHIFTER 7A 24 UPPER CASE
75. d 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 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 1 p Brush Paint gear marking compound evenly DIFFERENTIAL FRONT 7E 17 TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY Outer end Heel Drive side Coast side Inner end Toe NORMAL HIGH CONTACT Pinion is positioned too far from the center of driver bevel gear 1 Increase thickness of pinion height adjusting shim and position pinion closer to gear center 2 Adjust drive bevel gear backlash to specification Gear Pinion LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height
76. d transmission case 1 by measuring as shown in the figure Standard height difference a About 2 0 mm 0 079 in NOTE 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 Fit claws of thrust planetary rear washer and thrust planetary ring front race into holes securely Use care not to drop thrust planetary rear washer installed to O D planetary gear AUTOMATIC TRANSMISSION 4 A T 7B1 59 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
77. dle bearing 2 pieces bth gear needle bearing 2 pieces c o Jo Om RON 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 T LIS i AW SY 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 SUR gu pan Key slot width b Standard 10 1 mm 0 397 in Service limit 10 4 mm 0 409 in VM T Using feeler gauge check clearance between sleeve 1 and shifter fork 2 and replace parts if necessary Clearance between sleeve and shifter fork Maximum 1 0 mm 0 039 in Check chamfered part of each sleeve for damage and excessive wear and replace as necessary Check each synchronizer key and synchronizer spring and replace as necessary Check splined portions and replace parts if excessive wear are found MANUAL TRANSMISSION TYPE 1 7A 13 LOW AND REVERSE SCISSORS GEAR ASSEMBLIES IF EQUIPPED Check for the following items Match mark 3 provided for reassembly should be almost at such position as shown in the figure Try to turn scissors gear against main shaft low and reverse gear It should feel light when turned in A direction but heavy when
78. 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 with the clutch housing 7A 6 MANUAL TRANSMISSION TYPE 1 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 10 Remove center bearing plate 1 by removing its 2 bolts 2 CL IJ MANUAL TRANSMISSION TYPE 1 7A 7 11 Remov
79. e bolts 2 to specification 35 Torque counter shaft plate fixing bolt 1 applied with thread lock cement to specification NOTE After tightening bolts check input gear and output rear shaft for smooth rotation by hand at low and high speed position Also check front drive shift for proper operation Cement 99000 32020 Tightening torque Counter shaft plate bolt c 23 N m 2 3 kg m 17 0 Ib ft Front case bolt d 23 N m 2 3 kg m 17 0 Ib ft 3 Front case 36 Before assembling rear case 2 shim adjustment is required Follow steps described below 1 Center case 3 Rear shaft bearing No 1 4 Rear shaft bearing No 2 A B C Clearance 7D 20 TRANSFER 4WD 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 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 Obtain clearance in following calculation A D B D d Select a shim from among following available sizes and install it in bearing bore of rear case CAUTION Installing of over
80. e 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 Check companion flange for wear or damage Check bearings for wear or discoloration Check differential carrier for cracks Check drive bevel pinion and bevel gear for wear or cracks Check side gears pinion gears and pinion shaft for wear or damage Check side gear spline for wear or damage SUB ASSEMBLY ADJUSTMENT AND REAS SEMBLY 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 Bevel gear and pinion must be replaced as a set when either replacement becomes necessary 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 Special 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
81. e outside circlip 1 of front bearing 2 on counter shaft 12 Using plastic hammer drive counter shaft 1 rearward 13 Pull out 5th gear 2 and rear bearing 1 with bearing puller 3 and press NOTE Apply pressing force while adjusting position of front bearing so that it will fit in its original position hole in lower case 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 15 Pull out reverse gear 1 with bearing puller 2 and press 16 Pull out roller bearing by hand and then remove shaft from lower case 7A 8 MANUAL TRANSMISSION TYPE 1 17 Remove circlip 3 of counter shaft 1 front bearing 2 and pull out bearing 2 by using puller de N Special tool N Gun ER SAN 1 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 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 A 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
82. e wasted e E E ei sa JE S 1 Torque converter 6 Forward clutch input shaft 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
83. eck composite preload of pinion bearing and side bearing NOTE 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 side 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 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 Pinion bearing starting torque range Pinion bearing plus side bearing starting torque range 7F 16 DIFFERENTIAL REAR 63 8 50 4 33 6 Degree kg cm Degree 20 0 173 11 49 Drive bevel pinion bearing starting torque preload side bearing starting torque preload 15 0 713 0 42 7 10 0 amp 8 7 60 7 1 8 1 9 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 kg 7 9 11 3 14 7 lb in 9 0 13 0 17 0 kg cm Drive bevel pinio
84. ect 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 ee 2 1 Universal Joint flange P No 27110 60 00 Pinion dummy height Attachment height 2 Nut b Axle dummy radius 3 Front bearing 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 4 Differential carrier Measured dimension 5 Rear bearing d Differential carrier mounting distance Ca b 6 Spacer Bevel pinion mounting distance Marked in shaft in mm 7 Bevel pinion Shim size for mounting distance adjustment Cd e 8 Bevel gear DIFFERENTIAL REAR 7F 11 1 Install special tools with bearings and universal joint flange 2 to differential carrier 1 NOTE This installation requires universal joint flange 2 not equipped with groove on flange periphery This installa
85. eed sleeve Low gear Ball Needle bush Main shaft bearing 5th gear Counter shaft front bearing Counter shaft Counter shaft rear bearing Thrust washer Counter shaft 5th gear and hub 27 28 29 30 31 32 33 34 35 36 37 38 39 5th sleeve 5th speed synchronizer dog Reverse idle gear Reverse gear shaft Reverse gear shift plate 5th reverse gear shift shaft High gear shift shaft High speed gear shift fork Low speed gear shift fork Reverse gear shift yoke Low gear shift shaft Reverse gear shift shaft 5th gear shift shaft 5th gear shift fork Gear shift shaft inner lever Bolt Plug Gear shift inner shaft Locating screw Locating spring Locating ball Locating roller No 3 Locating roller No 2 Locating roller No 1 Reverse gear shift link comp 4746 45 7A1 4 MANUAL TRANSMISSION TYPE 2 1 Clutch housing 9 Reverse link stay 17 Main shaft oil seal 25 Spring pin 2 Blank 10 Transmission intermediate case 18 Return spring reverse bolt 26 Gear shift arm 3 Blank 11 Main counter shaft bearing plate 19 Interlock cam plug 27 Case plate 4 Input shaft bearing retainer 12 Back up light switch 20 Interlock cam pin 28 Gear shift lever case 5 Gasket 18 5th reverse interlock cam comp 21 Case plug 29 Gear shift control lever 6 Transmission front case 14 Return spring low bolt 22 Gear shift shaft 7 drain plug 15 Counter shaft gutter 23 Gear shift lever
86. ervice on or around 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 f 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 modules SDM and or seat belt with pretensioner beforehand to avoid component damage or unintended activation FOREWORD This manual provides information on the unit repair service procedures for the following units Applicable Units Manual Transmission Automatic Transmission Transfer Differentials Front and Rear for SQ416 SQ420 SQ625 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 produ
87. eturn system e Shift control lever Thread lock cement THREAD LOCK CEMENT SUPER 1333B Control lever locating bolts 99000 32020 Center case gutter bolt Rear case plate bolt Countershaft plate bolt Synchronizer plate screws Sealant SUZUKI BOND No 1215 Oil drain and level filler plugs 99000 31110 e Rubber plug Mating surface of front case Mating surface of rear case Mating surface of gear shift lever case 7D 24 TRANSFER 4WD SPECIAL TOOL 09900 06107 Snap ring plier Opening type 09900 06108 Snap ring plier Closing type 09912 34510 Separator 09913 75520 Bearing installer 09913 80112 Bearing installer V 09913 84510 Bearing installer lt 09921 57810 Bearing remover 09927 18411 Universal puller 09922 8581 1 Spring pin remover 09925 18011 Bearing installer 09925 98221 Bearing installer 09926 68310 Bearing installer 09940 53111 Bearing installer 09941 64511 Bearing remover 09951 16080 Bearing installer 09951 26010 Bush remover plate TRANSFER 4WD 7D 25 09951 76010 Bearing installer 7D 26 TRANSFER 4WD DIFFERENTIAL FRONT 7E 1 SECTION 7E DIFFERENTIAL FRONT CONTENTS GENERAL DESCHIPTION ne 7E 2 DIFFERENTIAL CARRIER 7E 8 COMPONENT rmm mene 7E 2 DIFFERENTIAL
88. front end set on special tool Special tool C 09913 80112 D 09944 66010 3 Lower case 5 Install bearing plate 1 applying thread lock cement 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 3 kg m 17 0 Ib ft 6 Washer aluminum 7 Counter shaft reverse gear 8 Counter shaft 5th gear 7A 24 MANUAL TRANSMISSION TYPE 1 ZEE IS es ra 7 After press fitting rear bearing 1 to counter shaft make sure to fit circlip securely Special tool E 09913 80112 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 Locating ball Rubber plug Reverse gear shift shaft Interlock ball Interlock pin High speed gear shift shaft P WD Low speed gear shift shaft 1 With fork installed to reverse gear shift shaft 1 install it into case and put in interlock ball 2 MANUAL TRANSMISSION TYPE 1 7
89. ft using a proper size rod 1 and press 14 Remove locating spring bolt 1 with washer 2 spring 3 and ball 4 for reduction shift Remove rubber plug 5 as well 15 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 TRANSFER 4WD 7D 7 16 Remove locating spring bolt 1 with washer 2 spring 3 and ball 4 for front drive shift 17 Pull out front drive shift fork 6 amp shaft 5 sleeve 7 and hub 8 all together NOTE Watch out for interlock steel ball which comes out from between 2 shift shafts so as not to lose it If it doesn t come out remove rubber plug and take it out 9 Output rear shaft 18 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 19 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 20 Using puller 3 and press remove bearing No 1 2 from shaft 1 7D 8 TRANSFER 4WD 21 Remove oil seal from center case 1 22 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
90. g 22 Place transmission upright as shown in the figure NOTE To prevent transmission case from getting damaged protect its contacting surface with stand by using shop cloth or the like 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 A AUTOMATIC TRANSMISSION 4 A T 7B1 9 29 Remove retaining ring 1 planetary gear assembly and leaf spring NOTE Use care not to cause damage to case when removing retaining ring 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 blowing 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
91. g 3 spacer 4 counter gear 2 steel balls b and washers 1 onto shaft 6 NOTE Washers must be installed with its oil slot side facing gear 26 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 A Grease 99000 25010 2 Counter gear 4 Washer 27 With circlip 2 placed on input gear 1 press fit input gear bearing 3 28 Fix bearing with circlip 4 Special tool D 09925 18011 E 09940 53111 H 09900 06107 29 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 30 Using special tool drive input gear assembly 2 into front case 1 Special tool 1 09951 16080 TRANSFER 4WD 7D 19 31 Fix with circlip 1 by means of snap ring pliers Special tool J 09900 06108 32 Oil to rotating parts and clean mating surfaces of center 1 case and front case 2 33 Apply sealant C to mating surface of front case 2 evenly and put cases together NOTE For smooth installation of front case apply grease to counter shaft O ring When mating front case make sure that input gear meshes with counter gear first Sealant 99000 31110 34 Torque 9 front cas
92. 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 10 MANUAL TRANSMISSION 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 removing 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 11 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 coun
93. h Secondary regulator 17 43 mm 71 27 mm valve spring 0 681 in 2 806 in Cut back valve spring 6 85 mm 23 00 mm 0 269 in 0 905 in Throttle valve 7 16 mm 19 24 mm secondary spring 0 282 in 0 757 in Throttle valve 10 90 mm 39 55 mm primary spring 0 429 in 1 557 in Install as many throttle valve compensating rings as written down when disassembled 7B1 46 AUTOMATIC TRANSMISSION 4 A T 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 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 47 REAR UPPER VALVE BODY 10 1 3 2 kickdown control valve plug 5 Rear upper valve body 9 Shift valve plug 18 Shift valve spring 2 Clutch sequence valve 6 Plate 10 2 3 shift valve 14 3 4 shift valve 3 Reverse brake sequence valve spring 7 Gasket 11 Shift valve spring 15 Shift valve spring 4 Needle roller 8 Retainer 12 1 2 shift valve DISASSEMBLY 1 Take out 6 valve body balls 1 2 Needle roller 7B1 48 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 c
94. ial Recommended SUZUKI product Use Part Number A T fluid Refer to Section 0B Automatic transmission Parts lubrication when installing Lithium grease SUZUKI SUPER GREASE C Retaining parts in place when assembling 99000 25030 Oil seal lips Oil pump O ring SUZUKI SUPER GREASE A Cable ends 99000 25010 Sealant SUZUKI BOND No 1215 Mating surface of transmission case 99000 31110 7B1 68 AUTOMATIC TRANSMISSION 4 A T SPECIAL TOOL 09920 76010 Snap ring opener 09941 84510 Bearing inner race remover 09918 4821 1 Oil pump remover 09918 48220 Oil pump remover attachment M8 09926 98320 Spring compressor No 1set 09926 98310 Clutch spring compressor 09900 20606 Dial gauge 09900 20701 Magnetic stand 09943 88211 Bearing installer TRANSFER 4WD 7D 1 SECTION 7D TRANSFER 4WD CONTENTS GENERAL DESCRIPTION 7D 2 ASSEMBLY tenni 7D 11 COMPONENTS eee 7D 2 TIGHTENING TORQUE SPECIFICATION 7D 23 UNIT REPAIR eene 7D 4 REQUIRED SERVICE MATERIAL 7D 23 70 4 SPECIAL 7D 24 COMPONENT INSPECTION 7D 2 TRANSFER 4WD GENERAL DESCRIPTION COMPONENTS Ex he ML Ls th IL nn dii j iw Ss PIG 10 9 8 11 12 13 17 19 1
95. 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 housing 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 60 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 1 O D clutch 2 O D brake 3 Forward clutch 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 sh
96. ing locating roller No 3 1 by magnet 2 insert low gear shift shaft 3 to intermediate case and low speed gear shift fork 7A1 36 MANUAL TRANSMISSION TYPE 2 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 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 mum 1 MANUAL TRANSMISSION TYPE 2 7A1 37 29 Drive pin into reverse gear shift link 1 and shaft 2 by using special tool Special tool C 09922 85811 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 inse
97. ing 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 Case plug may come off during above work If it is not possible to take out gear shift arm in above 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 5 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 Case plug may come off during above work f it is not possible to take out gear shift arm 9 in above step 4
98. ing plate of axle lock clutch fitted to differential left case Also check return spring 1 for settling Check teeth of axle lock clutch 2 fitted to differential right case for wear damage and any other faulty condition 1 Leftcase 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 REAS SEMBLY 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 Bevel gear and pinion must be replaced as a se
99. ion 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 64 AUTOMATIC TRANSMISSION 4 A T 39 Using a plastic hammer connect forward clutch applying tube 1 lube applying tube 2 reverse brake applying tube 3 and brake applying tube 4 in such order as shown in fig ure 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 1 Cutout 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 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 65 43 For J20 and H25 engines perform the following procedures J20 and H25 engines a Clea
100. lace Bushing thrust washer Flaw burr wear burning Replace Oil seal gasket Flawed or hardened seal ring Replace Worn seal ring on its periphery or Replace side Piston seal ring oil seal gasket Replace etc Gear Flaw burr Replace Worn gear tooth Replace Splined part Burr flaw torsion Correct with oil stone or replace Snap ring Wear flaw distortion Replace No interference Replace Thread Burr Replace Damage Replace Spring Settling sign of burning Replace Clutch disc brake disc Wear burning distortion damaged Replace claw Clutch plate brake plate Wear burning distortion damaged Replace claw Sealing surface where Flaw rough surface 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
101. lign match marks 1 on cap and carrier Screw in 2 side 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 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 sure to apply measuring tip of dial gauge 1 at right angles to convex side of tooth Measure at least 4 points on drive bevel gear periph ery As a practical measure the following would be recom mended to obtain specified backlash and side bearing preload at the same time 8 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 a
102. llation requires no spacer or oil seal 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 When setting dial gauge to mounting dummy tighten screw lightly Be careful not to overtighten it which will cause damage to dial gauge With dial gauge set turn dummy back and force by hand a couple of times and attain accurate 0 zero adjustment Itis 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 Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accu rately When dial gauge measuring tip extends from 0 zero position pointer turns counterclockwise Measured value may exceed 1 mm Therefore it is also necessary to know reading of short pointer
103. m 0 0023 in Using cylinder gauge 1 check inside diameter of each gear If its inside diameter exceeds specification replace it Inside diameter of gear Standard 1st gt s ES 44 015 44 040 mm 1 7329 1 7338 in 3rd gear is Check chamfered part of each sleeve for damage and excessive wear and replace as necessary Check each synchronizer key and synchronizer spring and replace as necessary Check splined portions and replace parts if excessive wear is found 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 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 10 0 25 mm 0 004 0 009 in 7A1 20 MANUAL TRANSMISSION TYPE 2 EI mt S T RES MAN MAN OD COUNTER SHAFT AND REVERSE IDLE GEAR 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 1 218
104. n 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 follows 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 1 Brush Paint gear marking compound evenly DIFFERENTIAL REAR 7F 17 TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY NORMAL Outer end Heel ae 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 bL shim and position pinion closer to gear center 2 Adjust drive bevel gear backlash to specification Gear Pinion LOW CONTACT Pinion is positioned too close to the center of d
105. n 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 range Then install shift 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 Shift switch lock bolt b 5 5 N m 0 55 kg m 4 0 Ib ft 7B1 66 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 installation 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 c
106. n 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 Refer to the first figure of FORWARD CLUTCH in this section When installing each component 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 1 Bearing race 5 Clutch disc 9 Direct clutch piston 2 Bearing 6 Clutch plate 10 Direct clutch inner piston 3 Retaining ring 7 Return spring 11 Direct clutch cylinder 4 Clutch backing plate 8 O ring PN 2 LP A PD K we 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
107. nd side bearing Special tool D 09922 75222 NOTE Standard preload is shown in the graph 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 Pinion bearing starting torque range 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 20 0 17 3 kg cm Ib in 15 0 13 0 7 10 0 8 7 63 89 50 4 33 6 Degree 11 4 Degree 42 7 60 7 18 19 20 2 1 22 2 3 2 4 2 5 2 6 27 2 8 2 9 3 03 1 32 3 3 3 4 kg NCC IE Tc DE 7 9 9 0 11 3 13 0 14 7 17 0 kg cm Ib in Drive bevel pinion bearing starting torque preloa
108. nsmission case bolts 35 3 5 25 5 Inner gear shift shaft bolt 39 3 9 28 5 Inner gear shift shaft plug 19 1 9 14 0 Return spring low reverse bolts 28 2 8 20 5 Clutch housing bolts 50 5 0 36 5 Transmission to transfer bolts 50 5 0 36 5 REQUIRED SERVICE MATERIAL Material Recommended SUZUKI product Part Number Lithium grease SUZUKI SUPER GREASE A Oil seal lips 99000 2501 0 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 nput 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 MANUAL TRANSMISSION TYPE 2 7A1 43 SPECIAL TOOL O 09912 34510 09913 75510 09940 51710 09940 54950 Case separator 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 C 09927 08220 09940 53111 09900 06107 09941 84510 Shaft remover Bearing installer Snap ring pliers Bearing inner remover opening type 09925 18011 Installer attachment 7A1 44 MANUAL TRANSMISSION T
109. nt case 1 and install it to inter mediate case 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 7A1 40 MANUAL TRANSMISSION TYPE 2 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 66000 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
110. oller 1 and install it to input shaft 2 Grease 99000 25010 MAIN SHAFT ASSEMBLY NOTE Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear Use new circlips on shaft for installation Don t reuse circlips 1 Assemble high speed synchronizer hub 3 sleeve 4 a o lt O springs 1 and keys 2 according to the following proce dure 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 Insert keys 2 in hub slots with depression side of keys face center of hub 3 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 NOTE Do not mix high and low speed synchronizer keys as dimensions are different A Boss B Key location teeth C Wider flange C gt C D Depression of key 2 Install synchronizer ring 1 by matching its key slots to keys as shown in the figure MANUAL TRANSMISSION TYPE 2 7A1 25 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 5
111. olts 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 DIFFERENTIAL REAR 7F 5 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 driv
112. ompressed remove circlip 1 and then remove fork 2 and spring 3 7D 10 TRANSFER 4WD 31 Remove center case gutter 1 with wrench 2 Center case COMPONENT INSPECTION Check each ball bearing for smooth rotation If found abnormal replace 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 Check needle bearing and bearing contacting surface for damage Replace as required Check gear tooth surface and shift mechanism in the same manner as with transmission Correct or replace as necessary Check drive chain and sprockets for abnormal wear or dam age Replace as required Check oil seal for 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 Check gear tooth surface of speedometer drive gear Replace if it is damaged TRANSFER 4WD 7D 11 Put the synchronizer outer ring 1 inner ring 3 and the cone 2 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 s
113. ontrol 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 shift valve and shift valve spring AUTOMATIC TRANSMISSION 4 A T 7B1 49 ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points Coil outer diameter and free length of each valve sprig should be as listed below Be sure to use each one of correct size Coil outer diameter and free length of each valve sprig 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 90 mm 29 15 mm 2 3 shift valve spring 0 350 in 1 147 in 3 4 shift valve spring Use new rear upper valve body gasket 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 50 AUTOMATIC TRANSMISSION 4 A T LOWER VALVE BODY
114. onverter BEARING AND RACE INSTALLATION DIAGRAM IS je cm pa 272 AUTOMATIC TRANSMISSION 4 A T 7B1 67 TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening part Nem kg m Ib ft Oil pump bolts 7 5 0 75 5 5 Upper Lower valve body bolts 55 0 55 40 Detent spring bolt Throttle cam bolt 7 5 0 75 5 5 Pressure relief valve bolts 55 0 55 40 Rear upper valve body plate bolts Solenoid valve No 1 Shift solenoid valve bolts 10 1 0 7 5 Solenoid valve No 2 TCC solenoid valve bolts Pressure relief valve bolt 55 0 55 40 Lower valve body plate bolts TCC Lock up control valve plates bolts Center support bolts 26 2 6 19 0 Torque converter housing bolts a 35 3 5 25 5 Torque converter housing bolts b 58 5 8 42 0 Parking lock pawl bracket screw 7 5 0 75 5 5 Valve body bolts 10 1 0 7 5 Oil screen bolts 5 5 0 55 4 0 Brake applying cover bolts 10 1 0 7 5 Oil pump assembly bolts 22 2 2 16 0 Oil pan bolts 4 5 0 45 3 3 Adapter case bolts G16 engine 35 3 5 25 5 Adapter case bolts J20 and H25 engines 42 4 2 30 0 Manual shift shaft set nut 4 0 4 3 0 Shift switch lock bolt 5 5 0 55 4 0 Oil pipe flare nuts 30 3 0 22 0 Oil filler tube bolt uH 23 2 3 170 Transfer to transmission bolts Drive plate bolts tightening torque 78 7 8 56 5 REQUIRED SERVICE MATERIAL Mater
115. pecial tool A 09900 06107 4 Align key slots of synchronizer ring and synchronizer keys and set input shaft assembly to main shaft assembly Check that input shaft assembly turns lightly 5 Fix with C ring to counter shaft rear bearing 6 Install counter shaft 1 and rear bearing 2 to intermediate case NOTE When installing bearing bring it so that its C ring side is at rear side of intermediate case as shown in the fig ure When fitting of intermediate case and bearing is tight tap outer race of bearing lightly and evenly with plastic hammer MANUAL TRANSMISSION TYPE 2 7A1 33 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 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 7A1 34 MANUAL TRANSMISSION TYPE 2 ie y gt D s 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
116. plying 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 Pinion 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 differen tial 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 NOTE Be sure to use bearing holder for the purpose of prot
117. r ring to main shaft 1 3 Press fit low speed sleeve and hub assembly 2 onto main shaft 1 with press 3 Special tool A 09927 08210 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 18011 2 Washer 3 Low gear MANUAL TRANSMISSION TYPE 1 7A 21 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 Reverse side thick 5th side thick Key position 5th side thick gt 8 Set steel ball and bearing washer 2 and insert reverse gear bush 3 needle bearing 4 and reverse gear 5 1 Bearing 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 3 Bush 11 Press fit bearing
118. 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 56 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 If it exceeds standard range replace reverse brake disc reverse brake plate or reverse brake backing plate 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 8 Install reverse brake reaction plate so that its lug with dent comes to the same position as leaf spring 1 Relief spring 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 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 aligning fluid holes 2 in center support and transmission case NOTE Unless retaining direct
119. rive bevel gear 1 Decrease thickness of pinion height adjusting np shim and position pinion farther from gear cen ter 2 Adjust drive bevel gear backlash to specification If adjustment is impossible replace differential carrier 1 Check seating of bevel gear or differential case Check bevel gear for runout 1 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 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 TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening part Nem kg m Ib ft Bevel gear bolts 85 8 5 61 5 Bearing cap bolts 85 8 5 61 5 Lock plate bolts 12 1 2 9 0 Differential case bolts 41 4 1 30 0 REQUIRED SERVICE MATERIAL Recommended SUZUKI product Part Number THREAD LOCK CEMENT SUPER 1333B 99000 32020 SUZUKI SUPER GREASE A 99000 25010 Material Use Thread lock cement Bevel gear bolts Differential case bolts Lithium grease Oil seal lips Sealant SUZUKI BOND NO 1215 99000 31110 Rear differential drain plug Mating surface of differential housing Mating surface of rear axle housing SPECIAL TOOL DIFFERENTIAL REAR 7F 19 09900 20606 Dial gauge 099
120. rt 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 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 3 Shiftlever 7 Drive in spring pin for shift arm 7A 16 MANUAL TRANSMISSION TYPE 1 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 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 Ou
121. rt 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 7A1 38 MANUAL TRANSMISSION TYPE 2 34 Insert 5th reverse gear shift shaft 1 to reverse gear shift yoke and drive pin into shaft and yoke Special tool C 09922 85811 35 Install locating balls locating springs and locating screw after checking free length of locating springs Free length of locating springs Standard Limit a 31 0 mm 30 1 mm 1 22 in 1 19 in 20 2 19 6 0 79 0 77 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 ZI MANUAL TRANSMISSION TYPE 2 7A1 39 38 Clean mating surface of fro
122. ry gear 1 With reverse brake reaction plate 2 fixed stationary turn front planetary gear 1 clockwise to check that 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 1 Manual valve 2 TCC solenoid valve Solenoid valve No 2 3 O ring 4 Detent spring Plate Spring Ball Shift solenoid valve A amp B Solenoid valve No 1 10 11 12 Gasket Lower valve body assembly Plate Front upper valve body 13 14 15 16 Rear upper valve body Intermediate coast modulator valve Low coast modulator valve By pass valve 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 oth ers 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 Front upper valve body assembly 1 Throttle valve keep plate 2 Locating pin 3 Cut back valve retainer Rear upper valve body assembly
123. ry to place support base at lower end of shaft Special tool D 09925 18011 G 09926 68310 19 After installing large size circlip 4 install speedometer drive gear 3 and secure it with small size circlip 2 1 Output rear shaft TRANSFER 4WD 7D 17 20 Install interlock steel ball 1 2 Front drive shift shaft 3 Center case 21 Fit sleeve 2 to reduction clutch hub 1 NOTE Circumferential groove mark thicker rail side which works as shift stopper should be inside rear Hub has no specific direction A Groove Inside Rear 22 Combine sleeve 8 amp hub to reduction shift shaft 6 assem bly and install them into center case 9 Then put locating ball 4 and spring 3 also into case and loosely install bolt 1 23 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 Sealant 99000 31110 2 Washer 7 Shift fork 24 If friction ring 2 has been removed from counter shaft 1 press fit 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 7D 18 TRANSFER 4WD 25 Install needle bearin
124. sembly 1 2 O D clutch cylinder 3 With O D clutch assembly 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 Snapring Front 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 Check that ball valve of clutch piston is not stuck 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 When installing thrust washer 1 bring i
125. sized shim beyond specification in the following table may cause tight rotation of rear shaft and consequential bearing damage Shim specification Clearance C Shim size 0 0 13 mm 0 0 005 in NO NEED 0 13 0 23 mm 0 005 0 009 0 1 mm 0 004 in 0 23 0 33 mm 0 009 0 013 in 0 2 mm 0 008 in 0 33 0 43 mm 0 013 0 017 in 0 3 mm 0 012 in 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 37 Clean mating surfaces of both center 2 and rear 1 cases again apply sealant to mating surface of rear case and put them together C Sealant 99000 31110 3 Install shim m TRANSFER 4WD 7D 21 38 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 39 For transfer for TYPE 2 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 M T f 5 5 N m 0 55 kg m 4 0 Ib ft b Fix reduction shift yoke with
126. spring pin 4 while aligning shift yoke with shift shaft as shown in the figure 3 Screwdriver 40 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 2 h x 41 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 42 Fix lead of 4WD switch 1 with clamp 43 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 44 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 45 Torque gear shift lever case bolts to specific
127. springs 1 and keys 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 10 Insert 2nd gear 2 needle bearing 3 and low speed sleeve hub assembly 4 with synchronizer ring to main shaft 1 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 MANUAL TRANSMISSION TYPE 2 7A1 27 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 Check the cut in needle bush and ball are engaged After installation check the 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 17 Select circlip 1 that will make its thrust clearance 0 1 mm 0 0039 in or less and install it Circlip
128. ssembly 2 2 Remove rear planetary thrust washer 1 reverse brake backing plate 2 reverse brake disc 3 and reverse brake gt 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 Refer to the first figure of PLANETARY GEARS AND OUT PUT SHAFT when installing each component Check seal sleeve ring for damage before installation and replace if damaged c Front Install planetary sun gear as shown in the figure 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 Install reverse brake reaction plate 2 to front planeta
129. t 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 FRONT UPPER VALVE BODY AUTOMATIC TRANSMISSION 4 A T 7B1 43 12 After installing manual valve 3 install detent spring 2 and plate 1 and tighten detent spring bolt to specified torque Tightening torque Detent spring bolt 5 5 N m 0 55 kg m 4 0 Ib ft 5 17 1 14 19 18 e 8 6 7 1 Front upper valve boy 6 Front valve end cover 11 Throttle valve cam 16 Locating pin 2 Cut valve retainer 7 Secondary regulator valve 12 Cam return spring 17 Down shift plug 3 Cut back plug 8 Secondary regulator spring 13 Cam spacer 18 Throttle valve secondary spring 4 Cut back valve 9 Throttle valve keep plate 14 Throttle valve 19 Throttle valve compensating ring 5 Spring 10 Washer 15 Throttle valve primary spring 7B1 44 AUTOMATIC TRANSMISSION 4 A T DISASSEMBLY 1 Remove throttle valve keep plate 1 2 Using screwdriver with vinyl tape or the like wound around its tip hold cut back valve plug and remove cut back retainer 1 with magnet Then
130. t align opening in retaining ring 2 with lug of direct clutch piston return spring at retainer Special tool A 09926 98310 1 Press AUTOMATIC TRANSMISSION 4 A T 7B1 27 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 Do not match opening 1 in retaining back plate ring with cutout 2 in direct clutch cylinder Install clutch backing plate with its grooved side facing the front 1 Groove 7B1 28 AUTOMATIC TRANSMISSION 4 A T CENTER SUPPORT A B G16 and J20 engines H25 engine Center support O ring B1 brake Second coast brake piston Piston return spring Snapring B1 brake plate B1 brake disc Clutch backing plate Retaining ring 14 Planetary sun gear Sealring 15 B2 brake hub assembly B2 Second brake brake piston B2 brake plate B2 brake disc AUTOMATIC TRANSMISSION 4 A T 7B1 29 DISASSEMBLY 1 Remove retaining ring Special tool A 09920 76010 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
131. t when either replacement becomes necessary 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 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
132. ter 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 32 Remove synchronizer ring needle bearing and counter shaft 5th gear 7A1 12 MANUAL TRANSMISSION TYPE 2 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 36 Remove main and counter shaft bearing plate 1 37 Remove C ring 1 of counter shaft rear bearing Special tool B 09900 06107 MANUAL TRANSMISSION TYPE 2 7A1 13 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 ca
133. ter spring MANUAL TRANSMISSION TYPE 1 7A 17 12 Install gear shift lever 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 Apply thread lock cement C to control lever locating bolts 1 when replaced Be sure to apply sealant to mating surface of gear shift lever for its final installation 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 nec essary carefully by using reamer oilstone and the like wash it thoroughly and reassemble them Items to be checked are Shift shaft should go into case smoothly 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 Cut off portion 5 in shift shaft should face downward when shift shaft 1 is installed Usecare for installing direction of shift limit spring 4 Shift arm should be installed at the same time 2 Shiftlever 3 Shift limit yoke 7A 18 MANUAL TRANSMISSION TYPE 1 3 Drive in
134. thickness specification ID mark 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 2 85 2 90 mm 0 1123 0 1141 in 2 91 2 96 mm 0 1146 0 1165 in 2 97 3 02 mm 0 1170 0 1188 in 3 03 3 08 mm 0 1193 0 1212 in 3 09 3 14 mm 0 1217 0 1236 in 3 15 3 20 mm 0 1244 0 1259 in 3 21 3 26 mm 0 1264 0 1283 in 3 27 3 32 mm 0 1288 0 1307 in r Ale I QO Tn m oO oO gt 2 Thickness gauge 18 Check low gear clearance referring to MAIN SHAFT ASSEMBLY in this section 7A1 28 MANUAL TRANSMISSION TYPE 2 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 Reverse side front 5th side Key position 5th side thick gt 2 Set inner race 2 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 3 Select circlip that will make its thrust clearance 0 1 mm
135. tion requires no spacer or oil seal ay Ve Special tool B 09926 78311 F 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 When setting dial gauge to mounting dummy tighten screw lightly Be careful not to overtighten it which will cause damage to dial gauge With dial gauge set turn dummy back and force by hand a couple of times and attain accurate 0 zero adjustment Itis 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 2 Screw 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 Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accu rately
136. ts oil groove 3 to the front When installing one way clutch to one way clutch outer race bring its flange 2 to the front 7B1 16 AUTOMATIC TRANSMISSION 4 A T Before installing piston inner O ring and piston outer O ring apply A T fluid to them Install so that snap opening and projection 1 of clutch pis ton return spring will not match 2 Slot 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 For installing cushion clutch plate 1 refer to the figure gt 2 Clutch cylinder side 3 Brake hub side AUTOMATIC TRANSMISSION 4 A T 7B1 17 OVERDRIVE CASE SIDE A G16 and J20 engines 3 Bearing race 7 Brake piston 11 Cushion plate B H25 engine 4 O D case 8 Return spring 12 Brake backing plate 1 Sealing 5 Planetary ring gear 9 Retainer 13 Brake disc 2 Bearing 6 O ring 10 Retaining ring 14 Brake plate 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 2 Remove retaining ring
137. turned in B direction 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 Scissors low gear Main shaft low gear Scissors reverse gear OD A N Main shaft reverse gear P WN Main shaft low or reverse gear Scissors low or reverse gear spring Scissors low or reverse gear Snapring Pin Main gear side Pin scissors gear side 7A 14 MANUAL TRANSMISSION TYPE 1 UPPER CASE AND SHIFTER 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 Check gear shift shaft for excessive wear and correct or replace a necessary 1 Locating groove 2 Yoke portion Check free length of each locating spring 1 and replace if it is below service limit Locating spring free length b Standard 27 0 mm 1
138. use main shaft assembly to come off forward 7A1 14 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 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 15 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 4 Press 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 4 Press 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 0f P i R J DD y Ss LA press 1 and rod diameter approx 22 mm 0 87 in 2 7A1 16 MANUAL TRANSMISSION TYPE 2
139. v 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 When shifted to reverse position or 5th position shifting of 1st 2nd speed or 3rd 4th speed is not available 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 MANUAL TRANSMISSION TYPE 1 7A 27 TRANSMISSION UNIT 1 Put main shaft input shaft assembly 7 into lower case 6 apply oil to component parts and check for proper engage ment smooth rotation with counter shaft 5 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 sacer nd d d 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 Scissors low gear if equipped Main shaft low gear Scissors reverse gear if equipped Main shaft reverse gear ak 3 Place bolts at their positions and che
140. ydraulic 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 Snap both ends of sun gear seal ring 1 securely Do not open sun gear seal ring more than necessary Always use new O ring and apply A T fluid before installa tion When installing O ring make sure that it is not kinked or caught Push in brake piston horizontally When installing brake piston return spring be careful so that spring will not fall or tilt AUTOMATIC TRANSMISSION 4 A T
141. ynchronizer outer ring 1 and each chamfered tooth of gear and synchronizer 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 in synchronizer outer ring Standard 10 1 mm 0 397 in Service limit 10 4 mm 0 409 in Check chamfered part of each sleeve 1 for damage and excessive wear and replace as necessary Using feeler gauge check clearance d between sleeve 1 and shift fork 2 and replace parts if necessary Clearance between sleeve and shift fork Maximum 1 0 mm 0 039 in Check each synchronizer key and synchronizer spring and replace as necessary Check splined portions and replace parts if excessive wear is found ASSEMBLY 1 Using press and special tool press fit needle bearing into center case 1 As shown in the figure apply straightedge 2 to top surface of case and press fit till limit line 3 of spe cial tool aligns with bottom surface of straightedge 2 i e case surface NOTE Press fitting needle bearing according to above proce dure will set needle bearing 3 mm before it hits case bottom 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

1998 Sidekick FSM - Drivetrain Manual

Contents

Download Pdf Manuals

Related Search

Related Contents