Main Shaft Assembly - Suzuki Grand Vitara XL-7 Service Manual

7A2-30 MANUAL TRANSMISSION

MAIN SHAFT ASSEMBLY

Check clearance "a" between synchronizer ring and gear, width of
index protrusion "b" in synchronizer ring, key slot width "c" in high
and low speed synchronizer hub and each chamfered tooth of gear
and synchronizer ring and replace with new one, if necessary. Also,
check gear tooth.
Clearance "a" between synchronizer ring and gear
(Main shaft):
1st:
Standard: 0.7 – 1.7 mm (0.028 – 0.067 in.)
Service limit: 0.5 mm (0.020 in.)
2nd:
Standard: 0.7 – 1.5 mm (0.028 – 0.060 in.)
Service limit: 0.5 mm (0.020 in.)
3rd:
Standard: 0.7 – 1.2 mm (0.028 – 0.047 in.)
Service limit: 0.5 mm (0.020 in.)
Width of index protrusion "b" (Main shaft):
1st:
Standard: 4.2 – 4.6 mm (0.165 – 0.181 in.)
Service limit: 4.0 mm (0.157 in.)
2nd:
Standard: 5.0 – 5.2 mm (0.197 – 0.205 in.)
Service limit: 4.8 mm (0.189 in.)
3rd:
Standard: 4.8 – 5.0 mm (0.189 – 0.197 in.)
Service limit: 4.6 mm (0.181 in.)
Key slot width "c" (High and low speed synchronizer hub):
Standard: 8.0 – 8.1 mm (0.315 – 0.319 in.)
D Measure width of high and low gear shift fork ends "a" and groove
width of high and low speed synchronizer sleeve "b" and then cal-
culate clearance "c".
If clearance exceeds limit, replace fork and sleeve.
Clearance "c" between fork and sleeve:
Standard: 0.3 – 0.5 mm (0.012 – 0.020 in.)
Limit: 1.0 mm (0.039 in.)