Get Manual Transmission (4-Speed) Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

MANUAL TRANSMISSION (4-SPEED) 7A-1

SECTION 7A

MANUAL TRANSMISSION (4-SPEED)

CONTENTS

GENERAL DESCRIPTION 7A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components 7A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 7A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 7A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Oil 7A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Shift Control 7A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT REPAIR OVERHAUL

7A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismounting/Remounting 7A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection of Transmission Components 7A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Steps in Reassembly 7A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REQUIRED SERVICE MATERIALS 7A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 7A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A-2 MANUAL TRANSMISSION (4-SPEED)

GENERAL DESCRIPTION

COMPONENTS

The transmission is fully synchronized and provides four forward speeds and one reverse speed by means of two

synchronizers and two shafts – input shaft and countershaft.

Gears on both shafts (input and counter) are always meshed. The low-speed synchronizer on the counter shaft

is engaged either with the low driven gear or second driven gear. The high-speed synchronizer is engaged with

either the third driven gear or top driven gear. The reverse idler gear is of clash-meshing type and is engaged with

the low speed synchronizer sleeve on the countershaft and the reverse drive gear on the input shaft.

Transmission case is in two-piece construction, consisting of upper case and lower case.

The lower case has the three-fork-shifting mechanism built in it.

The upper case houses the reverse shaft.

1. Final gear

2. Differential case

3. Side pinion

4. Side gear

5. Top gear

6. Third gear

7. Second gear

8. Low speed synchronizer sleeve

9. Low gear

10. Speedometer driven gear

11. Speedometer drive gear

12. Reverse idle gear

13. Reverse idle gear shaft

14. High speed synchronizer sleeve

15. Input shaft

16. Counter shaft

17. Countershaft nut

18. Clutch release bearing retainer

Apply SUZUKI SUPER GREASE A

(99500-25050) to inside of retainer

: Do not reuse

: Tightening Torque

: Apply SUZUKI SUPER GREASE

A (99000-25010)

: Apply SUZUKI BOND 1215

(99000-31110)

1. Speedometer driven gear

case

2. Speedometer driven gear

3. Counter shaft plug

4. Nut

5. Speedometer drive gear

6. Bearing

7. C ring

8. Thrust washer

9. Low gear

10. Needle bearing

11. Bush

12. Synchronizer ring

13. Synchronizer ring spring

14. Synchronizer spring

15. Low speed sleeve

16. Key

17. Low speed hub

18. Synchronizer ring

19. Thrust washer

20. Second gear

21. Needle bearing

22. Bush

23. Thrust washer

24. Spring

25. Third gear

26. Synchronizer ring

27. Synchronizer spring

28. High speed sleeve

29. Key

30. Thrust washer

31. High speed hub

32. Top gear

33. Needle bearing

34. Thrust washer

35. Bearing

36. C ring

37. Steel ball

38. Counter shaft

39. Pin

40. Plug

41. plug

42. C ring

43. Bearing

44. Input shaft

45. Bearing

46. Oil seal

47. Plug

48. Pin

49. Reverse shaft

50. Reverse idle gear

: Tightening Torque

: Do not reuse

: Apply SUZUKI SUPER GREASE A

(99000-25010)

MANUAL TRANSMISSION (4-SPEED) 7A-3

7A-4 MANUAL TRANSMISSION (4-SPEED)

DIAGNOSIS

Condition

Possible Cause Correction

Gears slipping out of mesh D Worn shift fork shaft

D Worn shift fork or synchronizer sleeve

D Weak or damaged locating springs

D Worn bearings on input shaft or countershaft

D Worn chamfered tooth on sleeve and gear

Replace.

Replace sleeve and gear.

Hard shifting D Inadequate lubricant

D Improper clutch pedal free travel

D Distorted or broken clutch disc

D Damaged clutch pressure plate

D Worn synchronizer ring

D Worn chamfered tooth on sleeve or gear

D Worn gear shift control shaft/extension rod

bush

D Distorted shift shaft

Replenish.

Adjust.

Replace.

Replace clutch cover.

Replace.

Replace sleeve or gear.

Replace.

Noise D Inadequate or insufficient lubricant

D Damaged or worn bearing(s)

D Damaged or worn gear(s)

D Damaged or worn synchronizer parts

Replenish.

Replace.

ON-VEHICLE SERVICE

TRANSMISSION OIL

D Check the transmission for oil leakage, each time when vehicle

is on hoist.

D Check the oil level according to the following procedures.

1) Take out the oil level gauge (1) from the transmission case

and wipe off the oil.

2) Bring face I of the oil level gauge to contact face II of the

transmission case and check the oil level indicated by the oil

on the gauge.

The oil level must be somewhere between FULL level line and

LOW level line on the gauge.

D When draining oil, be sure to remove 2 drain plugs (2).

D When installing drain plugs (2), apply sealant to the screw part

of the plug before reassembling and be sure to tighten the plug

to specification using hexagon socket.

Sealant : SUZUKI BOND NO.1215 (99000-31110)

Tightening Torque for oil drain plugs:

28 N·m (2.8 kg-m, 20 Ib-ft)

D When changing oil, fill transmission with new oil specified below.

NOTE:

For the vehicles used in the areas where the ambient tempera-

ture becomes lower than –155C (55F) during the coldest sea-

son, it is recommended that oil be changed with SAE 80W or

75W/80 – 85 oils on such occasion of services as a periodic

maintenance.

MANUAL TRANSMISSION (4-SPEED) 7A-5

Oil capacity

2.0 liters

(4.2/3.5 US/Imp. pt.)

Oil specification

Gear oil, SAE #90, SAE 80W or

SAE 75W 80 – 85

GEAR SHIFT CONTROL

1. Gear shift control lever knob

2. Gear shift control lever

3. Lever cover

4. Lever boot

5. Dust cover

6. Lever housing

7. Lever seat

8. Dust seal

9. Guide plate

10. Extension rod

11. Control shaft rear boot

12. Gear shift control shaft

13. Extension rod bush

Apply SUZUKI SUPER GREASE

A (99000-25010)

14. Control shaft joint

15. Control shaft rear bush

Apply SUZUKI SUPER GREASE

A (99000-25010)

16. Lever housing bolt

17. Lever housing nut A

18. Lever housing nut B

19. Extension rod nut

20. Control shaft nut

: Tightening Torque

: Do not reuse

: Apply SUZUKI SUPER GREASE

A (99000-25010)

7A-6 MANUAL TRANSMISSION (4-SPEED)

Removal

Gearshift control lever

Remove the gearshift control lever (1) according to the following

procedure.

1) Remove gearshift control lever housing nuts (4 pcs) and bolts

(2 pcs).

2) Lift the front end of vehicle by jacking, and support it on safety

stands.

3) Remove lever joint bolt.

4) Remove extension rod (1) with its bracket (2).

5) Pull out the gearshift control lever (3) downward.

Gearshift control shaft

To remove control shaft (1), remove bolt (2) connecting gearshift

control shaft and the gearshift shaft on the transmission side. Then

remove bolt (3) from the control shaft.

Inspection

Boots, dust seals and bushes

Check them for damage and wear. Replace if defective.

Gearshift lever housing

Check rubber for damage or crack and replace if defective.

Installation

Install in reverse order of removal, noting the following

D Apply enough grease to the positions referring to page 7A-6.

SUZUKI SUPER GREASE A 99000-25010

D Tighten bolts and nuts to specification referring to page 7A-6.

MANUAL TRANSMISSION (4-SPEED) 7A-7

Adjustment

Gear shift control lever adjustment

When each shift stroke is short, or when gears are not in complete

mesh, adjust the gear shift lever position as follows.

Loosen gear shift control housing nuts and guide plate bolts (1).

Adjust gear shift lever position by displacing it toward front and rear

so that each shift stroke is equal and each gear is in complete

mesh.

1. Guide plate bolt

2. Guide plate

3. Gear shift control lever

4. Right angle

5. Front side

Lubrication

Apply grease (SUZUKI SUPER GREASE A) to gear shift control

lever seal and control rod bushes periodically.

For greasing points, refer to page 7A-6.

7A-8 MANUAL TRANSMISSION (4-SPEED)

UNIT REPAIR OVERHAUL

DISMOUNTING/REMOUNTING

Dismount or mount transmission with engine referring to SECTION

6A “ENGINE MECHANICAL”, and separate or combine transmis-

sion and engine.

DISASSEMBLY

1) Remove back up light switch.

2) Remove clutch release bearing (1).

3) Remove clutch release shaft return spring (1) from release lever

(2).

4) Remove clutch release bearing retainer (1).

Inserting bolts in the upper and lower points of retainer will facili-

tate removal.

MANUAL TRANSMISSION (4-SPEED) 7A-9

5) Remove bolts fastening upper and lower cases.

6) Detach lower and upper transmission cases.

7) When upper case is removed, all parts should be left on the

lower case.

8) Remove input shaft assembly (1) from the lower case.

9) Remove counter shaft assembly (1) from the lower case.

10) Tap the spring pin out of the 3 shift fork shafts with special tool.

Special Tool

(A): 09922-85811

7A-10 MANUAL TRANSMISSION (4-SPEED)

11) Draw out 3 shift fork shafts in the order of low speed gear shift

fork shaft, high speed gear shift fork shaft and reverse gear

shift fork shaft.

NOTICE:

D The 2 shafts should be positioned at neutral when re-

moving shift fork shafts.

D Take care when drawing out shafts so that locating

balls do not fall out.

12) Fit special tool on low speed synchronizer sleeve and fix it se-

curely with a vice as shown below.

Loosen countershaft nut and draw out speedometer drive

gear.

Special Tool

(B): 09921-57810

13) Remove bearing. After removing bearing, all the parts on

counter shaft can be removed.

Special Tool

(C): 09913-61110

MANUAL TRANSMISSION (4-SPEED) 7A-11

INSPECTION OF TRANSMISSION COM-

PONENTS

Reverse gears and idle gear

Inspect the chamfered edges (1) of gear teeth of the three gears-

driving and driven gears (of input shaft and countershaft) and idle

gear. If the edges are worn badly, replace the gears. Abnormal

noise of gear slipping in reverse drive is often due to worn tooth

edges of these gears.

Input shaft and its bearings

If any of input shaft gears is found with chipped or broken teeth, re-

place input shaft. Check each bearing by spinning its outer race by

hand to “feel” the smoothness of rotation. Replace the bearing if

noted to exhibit sticking, resistance or abnormal noise when spun

or rotated by hand.

Check spline (1) of input shaft for wear and damage. Replace if de-

fective.

Combination of gear and synchronizer ring

Fit ring to cone of the gear (top gear, or “third”, “second” or “low”

gear), and measure the clearance between the two at the peripher-

al teeth, as shown in below figure. If the clearance has reached or

exceeds the service limit, replace the worn part.

Inspect the external cone (of gear) and internal cone (of ring) for

abnormal wear. Be sure that the contact patterns on these surfaces

indicate uniform full-face contact, and that the surfaces are from

any wavy wear. A badly worn member must be replaced.

Proper synchronizing action on gear shifting can be expected

when the ring-to-gear clearance and the condition of cone sur-

faces, among other things, are satisfactory.

1. Checking contacting surface

7A-12 MANUAL TRANSMISSION (4-SPEED)

Clearance between

Standard Service limit

Clearance

between

gear and ring

0.8 – 1.2 mm

(0.03 – 0.05 in.)

0.5 mm

(0.02 in.)

Chamfered tooth ends of ring (external teeth) and sleeve (in-

ternal teeth)

Synchronizer ring and hub have three slots each, in which keys are

carried as backed by expanding springs, so that hub and its two

rings, one on each end, are capable of running together. Since

sleeve is engaged by its internal teeth with hub, as if the two were

splined together, sleeve too runs with hub and rings.

In meshing action, sleeve is pushed (by the shifter fork) to one side,

so that it slides axially on hub, pushing ring toward cone surface of

gear. This push is transmitted by three keys, which are lightly

gripped by sleeve.

By the friction between gear cone and ring cone (internal), ring be-

gins to rotate but is opposed by hub because of the keys. In other

words, the ring is at this time twisted, while the sleeve is advancing

further to push the ring fully against the gear cone. Since the ring

is unable to slide along any further, the sleeve lets go of the keys

and rides over to the ring. At this moment, the initial contact be-

tween the chamfered ends of teeth of ring and those of internal

teeth of sleeve occurs. This contact is such that the internal teeth

of sleeve align themselves to those of the ring.

When the sleeve advances and slides into ring, ring will be rotating

nearly with the speed of gear, so that sleeve is enabled smoothly

to slide over into clutch teeth of gear.

The initial contactor mesh between sleeve and ring is determined

by widths of key and slot or, to say the same thing, key clearance

in the slot, and is prescribed to extend at least a third (1/3) of the

chamfer.

With the synchronizer properly assembled on shaft, push in and

twist each synchronizer to see if the one-third mesh occurs or not;

if not, it means that the overall wear (which is the sum of the wears

of slots, keys and chamfered tooth ends) is excessive and, in such

a case, the entire synchronizer assembly must be replaced.

MANUAL TRANSMISSION (4-SPEED) 7A-13

Mesh of chamfered tooth ends of

synchronizer ring and sleeve

Contact extending about 1/3 of

chamfered face from apex

Synchronizer rings

Inspect each synchronizer ring for key slot wear by measuring the

width of each slot. If the width reading exceeds the limit, replace the

ring.

Fork shaft locating springs, gear shift arm spring and shift

shaft locating spring

Locating springs are used to arrest the three shifter fork shafts. If

“gears slipping out of mesh” has been reported, check these

springs for strength by measuring their free lengths, and replace

them if their free lengths are less than the service limits.

Gear shift arm spring is used to arrest shift lever when it is shifted

into reverse gear.

Also replace it if its free length is less than the below specified ser-

vice limit.

7A-14 MANUAL TRANSMISSION (4-SPEED)

Key slot width Standard Service Limit

Low gear

8.0 mm

(0.31 in.)

8.3 mm

(0.32 in.)

Second gear

10.0 mm

(0.39 in.)

10.3 mm

(0.40 in.)

Third and top gear

9.6 mm

(0.38 in.)

9.9 mm

(0.39 in.)

Free length Standard Service Limit

Reverse fork shaft locating

spring, gearshift arm spring

and shift shaft locating spring

19.5 mm

(0.767 in.)

17.0 mm

(0.669 in.)

Low and High speed fork shaft

locating spring

17.0 mm

(0.669 in.)

15.5 mm

(0.610 in.)

Gear backlash

Check the backlash of gears with a fuse wire-element or dial gauge

and replace if the backlash exceeds the specified service limit.

Gear backlash

Shifter fork shafts

Check the groove of shifter fork shaft which comes in contact with

locating spring ball, for wear.

Differential case bolts

Check differential case bolts for looseness and retighten if loose.

Tightening Torque for Differential Case Bolts

90 N·m (9.0 kg-m, 65 Ib-ft)

MANUAL TRANSMISSION (4-SPEED) 7A-15

Gear Standard Service Limit

Low & Second

0.05 – 0.10 mm

(0.0019 – 0.0039 in.)

0.30 mm

(0.0118 in.)

Third & Top

0.15 – 0.20 mm

(0.0059 – 0.0078 in.)

0.30 mm

(0.0118 in.)

Reverse

0.15 – 0.30 mm

(0.0059 – 0.0118 in.)

10.3 mm

(0.40 in.)

Differential side pinion & gear

Measure the backlash of side pinion and side gear. To measure

backlash, insert a thin fuse between pinion and gear and measure

the thickness of the crushed fuse.

If the backlash exceeds the specified value, adjust it by varying the

thickness of thrust washer (1) at the back of side gear (back of the

toothed surface).

7A-16 MANUAL TRANSMISSION (4-SPEED)

Side gear back lash specification

0.05 – 0.10 mm

(0.002 – 0.004 in.)

Side gear thrust play specification

0.15 – 0.40 mm

(0.006 – 0.016 in.)

Available thrust washer sizes

(thickness)

0.8, 1.0 & 1.2 mm

(0.03, 0.04 & 0.05 in.)

IMPORTANT STEPS IN REASSEMBLY

NOTICE:

D Wash all parts and apply gear oil to sliding surfaces.

D When installing each parts on counter shaft, be careful for

installing direction and position of each washer, gear, syn-

chronizer ring, hub and sleeve.

Refer to figures in p. 7A-2 and 7A-3. Don’t forget to install

pin and ball on countershaft.

Synchronizer hub and synchronizer sleeve

When mounting low-speed and high-speed synchronizer hubs on

countershaft, direct the longer inner boss of each hub as shown in

below figure.

When inserting synchronizer sleeve in synchronizer hub:

Low-speed synchronizer sleeve:

Point groove (1) on the outer surface of sleeve in the direction of

the low gear side.

High-speed synchronizer sleeve:

Point groove (2) on the outer surface of sleeve in the direction of

the clutch side.

High-speed synchronizer sleeve Low-speed synchronizer

sleeve

Second and third gear bush

When assembling the second and third gear bush, make sure that

oil hole of counter shaft and oil grooves of second and third gear

bushes match accurately.

Synchronizer spring

Do not deform or otherwise damage synchronizer spring. To install

spring, insert one end of spring in the spring setting hole (3) on syn-

chronizer hub, directing 2 springs in opposition to each other so

that the load is evenly applied to synchronizer keys.

MANUAL TRANSMISSION (4-SPEED) 7A-17

Synchronizer ring

Three types of synchronizer ring are used.

Be sure to install them in place.

1. Low gear synchronizer ring

2. 2nd gear synchronizer ring

3. 3rd & top gear synchronizer ring

Be sure that three keys mounted on hub fit snugly into the slots pro-

vided in ring.

Synchronizer ring spring

Do not forget to install spring (1) between low gear synchronizer

ring (2) and synchronizer hub (3).

1. Synchronizer ring spring

2. Low gear synchronizer ring

3. Synchronizer hub

2ND, 3RD driven gear spring

Do not forget to install spring (1) between the 2nd and 3rd driven

gears on counter shaft. This prevents noise due to play.

7A-18 MANUAL TRANSMISSION (4-SPEED)

Low gear thrust washer ball

After installing low gear bush, bearing and low gear, install ball on

counter shaft.

Counter shaft bearing

To drive bearing into the counter shaft, use special tool.

Special Tool

(A): 09913-80112

Counter shaft nut

Fit special tool on low speed synchronizer sleeve and fix it securely

with a vice as shown below. And then tighten nut to the below speci-

fied tightening torque.

Special Tool

(A): 09921-57810

Tightening Torque for Countershaft Nut

70 N·m (7.0 kg-m, 40 Ib-ft)

1. Torque wrench

2. Vice

MANUAL TRANSMISSION (4-SPEED) 7A-19

In order to lock countershaft nut firmly, caulk nut with a chisel or the

like as its part over the groove in countershaft, as shown below.

NOTE:

The nut once used should never be used again.

1. Caulked portion of nut

Shifter forks and shafts

When mounting shifter fork on shifter shaft, refer to below figure for

the direction of shifter forks.

Locating springs are for keeping locating steel balls pushed down

against fork shafts (REVERSE, HIGH and LOW) for the purpose

of arresting these shafts at respective operating positions.

CAUTION:

D Locating steel balls and gear shift arm shaft steel ball

used have an outside diameter of 7.9 mm f (0.311 in. f).

D When installing locating springs, distinguish between

reverse locating spring and low & high ones by its free

length.

For their free length, refer to p. 7A-14.

Install shifter shaft in the order of reverse shaft (1), high-speed

shaft (2) and low-speed shaft (3), as shown in below figure.

7A-20 MANUAL TRANSMISSION (4-SPEED)

Insert interlock steel balls through shaft hole. Through this hole, in-

sert one ball between each of 2 adjacent shafts. Use interlock steel

balls with an outside diameter of 9.5 mm f (0.374 in. f).

NOTICE:

Be sure to put in pin for preventing two shafts from getting

shifted at the same time. This pin (1) goes into the hole pro-

vided in high-speed shaft.

Gear shifter fork and shaft stopper pins

Drive the shifter fork pins (low-speed, high-speed and reverse) into

the shifter fork and shaft completely.

Drive the shifter shaft stopper pins into the shifter shaft so that di-

mension H is obtained, as illustrated in below figure.

A : Shifter fork pin Length 20 mm 10.79 in.). . . .

A-1 : Shifter fork pin Length 18 mm 10.71 in.). . . .

B : Stopper pin Length 18 mm 10.71 in.). . . . . .

H : Low-speed stopper pin height 3 mm (0.12 in.)

H : High-speed stopper pin height 0 mm (0 in.)

H : Reverse stopper pin height 3 mm (0.12 in)

MANUAL TRANSMISSION (4-SPEED) 7A-21

Reverse gear shifter lever

When installing reverse gear shifter lever, adjust dimension “a” as

illustrated below to 5 mm (0.197 in.) with gear shifter lever bolt (1).

This is necessary to keep the clearance between lever and second

gear on input shaft to more than 2 mm (0.078 in.) when shifting gear

into reverse.

Gear shifter fork shaft plugs

Before installing gear shifter fork shaft plugs, apply SUZUKI BOND

NO. 1215 (99000-31110) to the outer surface of the plugs.

Caulk transmission case with punch as shown below to prevent

plugs from coming off.

1. Caulking

C ring

Do not forget to fit counter shaft bearing C-rings and input shaft C-

ring in transmission case.

Counter shaft

Install the countershaft in lower case with gears on countershaft in

neutral (shifter fork shafts must also be in neutral), fitting the shifter

fork in the groove of sleeve.

7A-22 MANUAL TRANSMISSION (4-SPEED)

Differential side bearing

Press-fit differential side bearing with a hydraulic press using spe-

cial tool. Direct the seal side (1) of the bearing (iron plate side) in-

ward (transmission oil side).

Special Tool

(A): 09913-75810

Differential case bolts

Special bolts are used for the differential case because of the high

torsional load. Never use bolts other than the specified ones.

Tightening Torque for Differential Case Bolts

90 N·m (9.0 kg-m, 65 Ib-ft)

Differential side oil seals

Apply grease to the lip of the differential side oil seal and install with

spring (1) of the oil seal positioned inside (transmission oil side).

Counter shaft bearing plug

Install the countershaft bearing plug, directing the rib (1) (flange)

of the plug outside the case, toward the joint of the upper and lower

cases on the differential side.

MANUAL TRANSMISSION (4-SPEED) 7A-23

Reverse gear shaft pin

Do not forget to install reverse gear shaft pin. After installation, ap-

ply grease to the hole into which pin has been inserted to prevent

the pin from coming out when combining upper and lower cases.

Do not install reverse idle gear in the wrong direction.

Putting together upper and lower cases

Clean the joint faces, removing any foreign matters adhering to

these faces, and then apply liquid sealing compound to the joint

faces, coating each face uniformly with the compound and, a few

minutes after this application, match the two cases together.

Sealant : SUZUKI BOND No. 1215, 99000-31110

[Clutch release shaft]

Before fitting upper case on lower case, apply grease to sliding sur-

faces between clutch release shaft and its bushes.

Lithium Grease : SUZUKI SUPER GREASE A

[Upper case]

Move idle gear to right and left so that idle gear fits perfectly in the

groove (1) of reverse idle gear shift arm when fitting upper case on

lower case.

7A-24 MANUAL TRANSMISSION (4-SPEED)

[Input shaft bearing retainer]

Bear in mind the following points when installing input shaft bearing

retainer.

D Apply grease to oil seal lip.

Lithium Grease : SUZUKI SUPER GREASE A (99000-25010)

D Install O-ring (1) in the groove of retainer and then apply sealant

to a part of the retainer that is lined up with the joint of upper and

lower transmission cases.

Sealant : SUZUKI BOND NO. 1215 (99000-31110)

D Before tightening transmission case bolts, insert the retainer into

the transmission case taking care not to damage O-ring (1).

D Apply grease to spline part of input shaft.

Lithium Grease : SUZUKI SUPER GREASE I (99000-25210)

After assembling, check to be sure that gear shift shaft can be

shifted to each gear position smoothly.

Clutch release arm

For release arm installation, refer to SECTION 7C “CLUTCH”.

Differential side gear snap rings

When replacing differential side gears, do not forget to install snap

rings (right and left) on differential side gear spline.

Oil drain plug and transmission oil

Install drain plug and fill transmission oil referring to 7A-5.

MANUAL TRANSMISSION (4-SPEED) 7A-25

09913-75810

Bearing installer

09913-80112

Bearing installer

09913-84510

Bearing installer

09922-85811

Spring pin remover

09913-61110

Bearing puller

09921-57810

Bearing remover

7A-26 MANUAL TRANSMISSION (4-SPEED)

REQUIRED SERVICE MATERIALS

MATERIALS

RECOMMENDED

SUZUKI PRODUCTS

USE

Lithium grease

SUZUKI SUPER GREASE A

(99000-25010)

SUZUKI SUPER GREASE I

(99000-25210)

D Oil seal lips

D Gear shift control lever

D Gear shift control shaft bushes

D Input shaft spline and front end

Sealant

SUZUKI BOND NO.1215

(99000-31110)

D Oil drain plug

D Gear shift shaft bolt

D Mating surface of transmission case

D Mating surface of clutch release bearing re-

tainer

SPECIAL TOOLS

Manual Transmission (4-Speed) for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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