Main Shaft Reassembly - Suzuki Grand Vitara 2011 Manual

Main Shaft Reassembly

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.
Do not reuse circlips.
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one as
necessary.
2) Apply oil to reverse gear needle bearing (1), and
then install needle bearing, reverse gear (2) and
reverse gear synchronizer ring (3) to main shaft.
3) Assemble 5th & reverse synchronizer sleeve (4),
synchronizer key (5), synchronizer key spring (6)
and hub (7) as shown in figure.
Manual Transmission/Transaxle: For Diesel Engine Model 5B-64
4) Drive in 5th & reverse synchronizer assembly (1)
S6JB0A5226024 using bearing puller, special tools and hydraulic
press.
Special tool
(A): 09913–85210
(B): 09945–55410
(C): 09940–54910
5) Select circlip (1) that will make thrust clearance "a" of
synchronizer hub 0.15 mm (0.006 in) or less and
install it.
Available circlip thickness
1.86 mm (0.073 in.)
1.95 mm (0.077 in.)
6) Apply oil to 5th gear needle bearing, and then install
needle bearing, 5th gear (1) and 5th gear
synchronizer ring to main shaft.
7) Drive in main shaft bearing (2) using bearing puller,
I5JB0B520107-01
special tools and hydraulic press.
Special tool
(A): 09913–85210
(B): 09945–55410
(A)
(B)
1
(C)
2.04 mm (0.080 in.)
(A)
(B)
2
1
I5JB0B520071-01
I5JB0B520072-02
I5JB0B520073-01