Fifth Gear Disassembly And Reassembly - Suzuki SX4 Service Manual

10. Oil drain plug
: Apply sealant 99000-31260 to all around thread part of plug.
11. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
12. Left case plate bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
13. Side cover bolts
14. Transaxle case bolts
15. 5th speed synchronizer ring
16. 5th speed synchronizer lever
17. 5th speed sleeve & hub
18. Circlip
19. Bearing set shim
20. Countershaft 5th gear
21. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.

Fifth Gear Disassembly and Reassembly

Disassembly
1) Remove cover bolts and take off transaxle side
cover.
CAUTION
!
Care should be taken not to distort side cover
when it is removed from left case.
2) Using special tool, remove circlip (1).
Special tool
: 09900–06107
3) Remove shift fork shaft bolt (2).
4) Remove gear shift fork (3) and 5th gear all together.
Use gear puller for removal if spline fitting of hub is
tight.
3
2
1
31. Reverse shaft bolt
32. Washer
33. Oil seal
34. Outer race
35. Shim
36. Oil gutter
5) Unfasten caulking of countershaft nut (2), install
S7RW0A5206015
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and
then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
I4RH01520015-01
Manual Transmission/Transaxle:
: Apply sealant 99000-31260 to thread part of bolt.
: Apply SUZUKI SUPER GREASE A
99000-25010 to Oil seal lip.
: 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
: 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
: Do not reuse.
: Apply transaxle oil.
1
5B-17
(A)
2
I4RH01520016-01
I4RH01520017-01