Suzuki Grand Vitara XL-7 Service Manual page 386

7A2-38 MANUAL TRANSMISSION
6) Check 3rd gear (2) thrust clearance by using thickness gauge
(1). If clearance is out of specification, repress or replace weary
part.
3rd gear thrust clearance:
Standard: 0.10 – 0.25 mm (0.004 – 0.009 in.)
7) Assemble low speed synchronizer hub (3), sleeve (4), springs
(1) and keys (2) according to the following procedure.
a) Install compression springs (1) and shifting keys (2) to low
b) Slide low speed synchronizer hub (3) in sleeve (4) so that
A: Key location tooth
B: Chamfered side
C: Dent
D: 2nd gear side
8) Assemble 2nd gear (1), synchronizer inner ring (2), synchroniz-
er cone ring (3) and synchronizer outer ring according to the fol-
lowing procedure.
a) Install synchronizer inner ring (2) to 2nd gear (1), fitting pro-
b) Install synchronizer outer ring (1) to 2nd gear (3), fitting slot
speed synchronizer hub (3) as shown in the figure.
chamfered side of sleeve (4) and dent side of hub (3) face op-
posite as shown in the figure, also aligning hub slots with key
location teeth of sleeve (4).
trusion of synchronizer cone ring (3) into groove of 2nd gear
(4), then attach synchronizer cone ring to 2nd gear as shown
in the figure.
of synchronizer outer ring (1) in protrusion of synchronizer in-
ner ring (2) as shown in the figure.