1998-2003 Suzuki Alto 4 Door Manual Transmission (4-Speed) -> On-Vehicle Service User Manual
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Manual Transmission (4-Speed) -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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)

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