1998-2003 Suzuki Alto 4 Door Manual Transmission (4-Speed) -> Unit Repair Overhaul User Manual
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Manual Transmission (4-Speed) -> Unit Repair Overhaul for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

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