Get Manual Transmission (5-Speed) Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

MANUAL TRANSMISSION 7A1-1

7A1

GENERAL DESCRIPTION 7A1- 2. . . . . . . . . . .

DIAGNOSIS 7A1- 6. . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 7A1- 7. . . . . . . . . . . . .

Oil Change 7A1- 7. . . . . . . . . . . . . . . . . . . . . . .

Differential Side Oil Seal 7A1- 8. . . . . . . . . . . .

Gear Shift Control 7A1- 9. . . . . . . . . . . . . . . . .

UNIT REPAIR OVERHAUL 7A1-10. . . . . . . . . . .

Dismounting/Remounting 7A1-10. . . . . . . . . . .

Disassembling Unit 7A1-10. . . . . . . . . . . . . . . .

Fifth gears 7A1-10. . . . . . . . . . . . . . . . . . . . . .

Gear shifter, main shaft and

countershaft 7A1-11. . . . . . . . . . . . . . . . . . .

Right case 7A1-13. . . . . . . . . . . . . . . . . . . . . .

Sub Assembly Service 7A1-15. . . . . . . . . . . . .

Right case 7A1-15. . . . . . . . . . . . . . . . . . . . . .

Left case 7A1-16. . . . . . . . . . . . . . . . . . . . . . .

Input shaft assembly 7A1-16. . . . . . . . . . . . .

Countershaft assembly 7A1-19. . . . . . . . . . .

Gear shifter 7A1-22. . . . . . . . . . . . . . . . . . . . .

Differential assembly 7A1-24. . . . . . . . . . . . .

Assembling Unit 7A1-26. . . . . . . . . . . . . . . . . . .

Differential to left case 7A1-26. . . . . . . . . . . .

Fifth gears 7A1-29. . . . . . . . . . . . . . . . . . . . . .

Gear shift & select shaft assembly 7A1-32.

REQUIRED SERVICE MATERIALS 7A1-33. . .

SPECIAL TOOLS 7A1-34. . . . . . . . . . . . . . . . . . .

SECTION 7A1

MANUAL TRANSMISSION (5-SPEED)

CONTENTS

7A1-2 MANUAL TRANSMISSION

GENERAL DESCRIPTION

The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three

shafts – input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses

a sliding idler gear arrangement.

1. Input shaft

2. 5th speed sleeve & hub

3. Input shaft 5th gear

4. Input shaft 4th gear

5. High speed sleeve & hub

6. Input shaft 3rd gear

7. Left case

8. Reverse gear shaft

9. Reverse idler gear

10. Right case

11. Countershaft

12. Left cover

13. Countershaft 5th gear

14. Countershaft 4th gear

15. Countershaft 3rd gear

16. Countershaft 2nd gear

17. Low speed sleeve & hub

18. Countershaft 1st gear

19. Final gear

20. Differential case

21. Differential side oil seal:

Apply lithium grease 99000-25010 to oil

seal lip.

22. Reverse shaft bolt:

Apply thread lock cement 99000-32110

to joint seam of reverse gear shaft.

23. Countershaft nut

24. Transmission case bolt

25. Bevel gear bolt

26. Left cover bolt

: Tightening Torque

: Do not reuse

MANUAL TRANSMISSION 7A1-3

1. Input shaft

2. Oil seal

3. Input shaft right bearing

4. Input shaft 3rd gear

5. 3rd & 4th gear bearing

6. High speed synchronizer ring

7. High speed synchronizer spring

8. High speed sleeve & hub

9. High speed synchronizer key

10. Circlip

11. Input shaft 4th gear

12. Input shaft left bearing

13. Input shaft 5th gear

14. 5th gear spacer

15. 5th gear bearing

16. 5th speed synchronizer ring

17. Washer

18. 5th synchronizer spring

19. 5th speed sleeve & hub

20. 5th synchronizer key

21. 5th synchronizer hub plate

22. Circlip

23. Reverse gear shaft

24. Reverse idler gear

25. Reverse shaft washer

26. Countershaft right bearing

27. Countershaft

28. Countershaft 1st gear

29. 1st gear synchronizer ring

30. Low speed synchronizer spring

31. Low speed sleeve & hub

32. Low speed synchronizer key

33. Circlip

34. 2nd gear synchronizer ring

35. 1st & 2nd gear bearing

36. Countershaft 2nd gear

37. Countershaft 3rd gear

38. 3rd & 4th gear spacer

39. Countershaft 4th gear

40. Countershaft left bearing

41. Bearing set shim

42. Countershaft 5th gear

43. Countershaft nut

44. Reverse shaft bolt:

Apply thread lock cement 99000-32110 to

joint seam of reverse gear shaft.

: Tightening Torque

: Do not reuse

7A1-4 MANUAL TRANSMISSION

1. Reverse gear shift arm

2. Reverse gear shift lever

3. 5th & REV gear shift guide shaft

4. 5th & REV gear shift shaft

5. High speed gear shift shaft

6. Low speed gear shift shaft

7. Gear shift & select lever

8. 5th & REV gear shift cam

9. 5th to REV interlock guide bolt

10. Gear shift guide case

11. Gear shift interlock plate

12. Gear shift interlock bolt:

Apply thread lock cement

99000-32110 to thread part

13. Gear shift & select shaft

14. Gear shift arm

15. Gear shift yoke

16. Gear shift shaft

17. Reverse gear shift lever bolt

18. Gear shift arm bolt:

Apply thread lock cement

99000-32110 to thread part

: Tightening Torque

GEAR SHIFT MECHANISM

Movement of gear shift control lever is transmitted to gear shift shaft through gear shift control shaft, and gear shift

& select shaft through gear shift arm and gear shift yoke, and then gear shift & select lever to each gear shift yoke,

shaft and fork or arm. Gear shift interlock plate is provided to prevent the gear from engaging double.

5TH & REVERSE GEAR SHIFT CAM

5th & reverse gear shift cam, cam guide return spring and 5th to re-

verse interlock guide bolt are provided to prevent the gear from be-

ing directly shifted from 5th to reverse.

MANUAL TRANSMISSION 7A1-5

4. Gear shift guide

case plate

5. REV select spring

(Compressed)

6. Gear shift & select

lever (In 5th position)

2. Shift cam

3. Return spring

(Expanded)

4. Case plate

5. REV select spring

(Expanded)

6. Shift & select

lever (N of

3rd – 4th position)

7. Guide bolt

3. Return spring

(Compressed)

4. REV select spring

(Compressed)

1. Shift & select shaft

3. Return spring

(Compressed)

4. REV select spring

(Compressed)

5. Shift & select lever

(In REV position)

6. Guide bolt

1) When gear is shifted to 5th speed, 5th & reverse gear shift cam

(2) turns clockwise with gear shift & select shaft (1) and it is

pushed up by cam guide return spring (3) to the position where

interlock guide bolt (7) prevents the cam from being shifted to re-

verse straight.

2) Shifting from 5th to neutral is available and further shift to re-

verse is interrupted.

However, when shift & select shaft (1) is moved to neutral of 3rd

– 4th position, shift limit cam mechanism is canceled as shown

in figure.

3) Selected position in neutral of 5th – REV is shown in figure.

While shift & select shaft (1) moves up to allow shift & select le-

ver (5) to shift in 5th or reverse position, shift cam (2) stays be-

cause of interference of guide bolt (6).

4) Now the mechanism is ready to be shifted to reverse without in-

terference of shift cam (2).

7A1-6 MANUAL TRANSMISSION

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 joint 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.

MANUAL TRANSMISSION 7A1-7

1. Drive shaft (LH)

ON-VEHICLE SERVICE

OIL CHANGE

1) Before changing or inspecting oil, be sure to stop engine and lift

vehicle horizontally.

2) With vehicle lifted up, check oil level and leakage.

If leakage exists, correct it.

3) Drain old oil and torque drain plug (2) as specified below. Apply

sealant to thread of drain plug before installation.

“A”: Sealant 99000-31110

Tightening Torque

(a): 21 N

m (2.1 kg-m, 15.5 lb-ft)

4) Fill new specified oil by specified amount (up to level hole).

NOTE:

D It is recommended to use API GL-4 75W-90 gear oil.

D Whenever vehicle is hoisted for any other service work

than oil change, also be sure to check for oil leakage.

Oil specification: API GL-4

For SAE classification, refer to viscosity

chart at the left.

Oil capacity: 2.1 liters (4.5/3.7 US/Imp. pt)

5) Apply sealant to thread of level/filler plug (3) and torque it as spe-

cified.

“A”: Sealant 99000-31110

Tightening Torque

(a): 21 N

m (2.1 kg-m, 15.5 lb-ft)

DIFFERENTIAL SIDE OIL SEAL

REPLACEMENT

1) Lift up vehicle and drain transmission oil.

2) Remove wheel, and disconnect tie-rod end from knuckle refer-

ring to SECTION 3D.

7A1-8 MANUAL TRANSMISSION

3) Remove stabilizer referring to SECTION 3D.

4) Remove ball stud bolt and then separate suspension arm from

knuckle.

5) By using flat end rods or the like, pull out drive shaft joint so as

to release snap ring fitting of joint spline at differential side.

Pushing knuckle portion outward, detach drive shaft at differen-

tial side.

1. Drive shaft

2. Flat end rod or the like

6) Remove oil seal and install a new one until it becomes flush with

case surface by using special tool and hammer.

NOTE:

When installing oil seal, face its spring side inward.

Special Tool

(A): 09913-75810 (for right side oil seal)

09913-75520 (for left side oil seal)

7) Apply grease to oil seal lip and at the same time check drive

shaft where oil seal contacts and make sure of its smoothness.

“A”: Grease 99000-25010

1. Differential side oil seal

8) Insert drive shaft joint to differential gear. Refer to Section 4.

9) Connect ball stud with knuckle and fasten with bolt to specifi-

cation, refer to Section 3D.

10) Connect tie-rod end with knuckle and fasten castle nut to spe-

cified torque, refer to Section3D.

Install split pin and bend it.

11) Install stabilizer mount brackets, fasten bolts to specified

torque referring to Section 3D.

12) Fill transmission oil as specified and make sure that oil has

been sealed with oil seal.

CAUTION:

D Be careful not to scratch oil seal lip with drive

shaft joint while inserting.

D Make sure to insert drive shaft joint fully and seat

its snap ring as it was.

D Do not hit joint boot with hammer or the like. Noth-

ing but hands is allowed to use when inserting

joint.

MANUAL TRANSMISSION 7A1-9

GEAR SHIFT CONTROL

For Removal/Installation, refer to the same item described in SEC-

TION 7A.

7A1-10 MANUAL TRANSMISSION

UNIT REPAIR OVERHAUL

DISMOUNTING/REMOUNTING

Dismount or mount transmission with engine, referring to SEC-

TION 6A “ENGINE MECHANICAL”, and separate or combine

transmission and engine.

DISASSEMBLING UNIT

FIFTH GEARS

1) Remove 8 bolts and take off transmission side cover.

2) Using special tool, remove circlip (1) and then hub plate (2).

CAUTION:

Care should be taken not to distort side cover when it is

removed from left case.

Special Tool

(A): 09900-06107

3) Remove shift fork plug (1) and guide ball (2).

NOTE:

Use of magnet would facilitate removal of guide ball.

4) Drive out spring pin (3) by using special tool and hammer.

Special Tool

(B): 09922-85811

5) Remove circlip (4).

6) Remove gear shift fork (1), sleeve & hub assembly (2), synchro-

nizer ring spring, synchronizer ring and 5th gear all together.

CAUTION:

Be careful not to pinch synchronizer ring spring when re-

moving.

MANUAL TRANSMISSION 7A1-11

7) Remove counter shaft nut (1) as follows:

a. Shift low speed gear shift shaft (2) to 1st gear position and

high speed gear shift shaft (3) to 3rd gear position.

b. Loosen nut with above double engagement.

NOTE:

Do not reuse counter shaft nut.

8) Remove input shaft 5th gear, needle bearing and counter shaft

5th gear. Gear puller would be necessary if spline fitting of count-

er shaft 5th gear is tight.

9) Remove 5 screws and take off left case plate (1), and then re-

move bearing set shim (2).

GEAR SHIFTER, MAIN SHAFT AND COUNTERSHAFT

1) Remove 3 bolts from left case cap and then take off cap.

2) Remove gear shift yoke bolt (1).

7A1-12 MANUAL TRANSMISSION

3. Transmission case bolt1. Left case

2. Right case

3) Remove gear shift fork shaft bolt (1) with washer, then take out

locating spring and steel ball.

4) Remove 4 bolts from gear shift guide case (2), and then re-

move wiring harness clamp bracket and guide case.

5) Remove gear shift interlock bolt (3) with washer.

6) Remove back up light switch (4).

NOTE:

Removal of 5th to REV interlock bolt (5) is not necessary

for removing gear shift & select shaft assembly.

7) Pull out gear shift & select shaft assembly (1).

8) Remove reverse shaft bolt (4) with washer.

9) Remove 11 case bolts from outside and another 4 from clutch

housing side.

10) Tapping left case flanges with plastic hammer, remove left

case.

11) Remove 2 gear shift fork shaft bolts (1) with washers, then take

out locating springs and steel balls.

MANUAL TRANSMISSION 7A1-13

12) Remove gear shift yoke (1).

13) Pull out reverse gear shaft (2) with washer, then take off re-

verse idler gear (3).

14) Pull out 5th & REV gear shift guide shaft (4) together with 5th

& REV gear shift shaft (5).

NOTE:

When removing 5th & REV gear shift shaft and guide shaft,

push up high speed gear shift shaft and shift it to 4th to fa-

cilitate removal of 5th & REV shifter.

15) Tapping input shaft (1) end with plastic hammer, push it out as

assembly from case a little, then take out input shaft assembly,

counter shaft assembly (2), high speed gear shift shaft (3) and

low speed gear shift shaft (4) all at once.

16) Remove countershaft L bearing cup from left case (5).

17) Remove differential side L oil seal also from left case.

RIGHT CASE

1) Remove speedometer driven gear assembly.

2) Remove differential gear assembly from right case.

7A1-14 MANUAL TRANSMISSION

3) Remove input shaft oil seal (1) by using special tools (combina-

tion of bearing remover and sliding shaft).

Special Tools

(A): 09930-30102

(B): 09923-74510

4) Also pull out countershaft R bearing cup (2) by using bearing re-

mover 09941-64511 with sliding shaft 09930-30102.

NOTE:

If counter shaft R bearing has been left in right case, pull it

out by using bearing remover 09923-73210 with sliding

shaft 09930-30102.

5) Remove bolt (1) and then pull out gear shift arm (2).

6) Remove gear shift shaft bolt (1) with washer (2), then take out

spring (3) and steel ball (4).

7) Remove gear shift shaft (5), boot (6) and oil seal (7).

8) Remove differential side R oil seal from right case.

MANUAL TRANSMISSION 7A1-15

A: Breather (Bring it downward)

SUB ASSEMBLY SERVICE

RIGHT CASE

1) Install input shaft oil seal (1) facing its spring side upward.

Use special tool and hammer for installation and apply grease

to oil seal lip.

“B”: SUZUKI SUPER GREASE A, 99000-25010

Special Tool

(A): 09951-76010

2) Install countershaft R bearing cup (2) by using special tools and

hammer.

Special Tools

(B): 09924-74510

(C): 09925-68210

3) Apply grease to gear shift shaft oil seal (1) at its lip and install it

up to bottom of the bore by using special tool and hammer.

“B”: SUZUKI SUPER GREASE A, 99000-25010

Special Tool

(D): 09925-58210

4) Install gear shift shaft (1), boot (2), steel ball, spring and tighten

bolt (3) with washer applied with sealant.

“C”: SUZUKI BOND NO.1215, 99000-31110

Tightening Torque

(a): 13 N

m (1.3 kg-m, 9.5 lb-ft)

NOTE:

Bring breather of gear shift shaft boot downward.

5) Install differential side R oil seal (4) until it becomes flush with

case surface by using special tool with hammer, and then apply

grease to its lip.

NOTE:

Face diff. side oil seal spring side inward.

“B”: SUZUKI SUPER GREASE A, 99000-25010

Special Tool

(E): 09913-75810

7A1-16 MANUAL TRANSMISSION

6) Insert gear shift arm (1) in gear shift shaft (2), then fasten them

with bolt applied with thread lock cement.

Tightening Torque

(c): 34 N

m (3.4 kg-m, 24.5 lb-ft)

“A”: Thread lock 1322, 99000-32110

LEFT CASE

1) If input oil gutter has been removed, install it with bolt applied

with thread lock cement.

“A”: Thread lock 1322, 99000-32110

Tightening Torque

(a): 10 N

m (1.0 kg-m, 7.5 lb-ft)

2) Install differential side L oil seal (1) until it becomes flush with

case surface by using special tool with hammer, and then apply

grease to its lip.

NOTE:

Face oil seal spring side inward.

“B”: SUZUKI SUPER GREASE A, 99000-25010

Special Tool

(A): 09913-75510

3) Install countershaft L bearing cup into case bore by tapping it

with plastic hammer lightly.

INPUT SHAFT ASSEMBLY

Disassembly

1) Remove input shaft R bearing (1) by using bearing puller (2) and

press.

MANUAL TRANSMISSION 7A1-17

2) Drive out 5th gear spacer (1), L bearing (2) and 4th gear (3) all

at once by using puller (4) and press.

CAUTION:

D To avoid gear tooth from being damaged, support it at

flat side of bearing puller.

D Stop press work in the middle way and take out 5th gear

bush to prevent it from being compressed and then

continue to remove bearing with gear.

3) Take out 4th gear needle bearing and high speed synchronizer

ring.

4) Using special tool, remove circlip (1).

NOTE:

For smooth removal of circlip, it is recommended to correct

tool tips to be flat.

Special Tool

(A): 09900-06107

5) Drive out high speed synchronizer sleeve & hub assembly (1)

together with 3rd gear (2) by using puller (3) and press.

CAUTION:

Make sure to use flat side of puller to avoid causing dam-

age to 3rd gear tooth.

6) Take out 3rd gear needle bearing from shaft.

7) Disassemble synchronizer sleeve & hub assembly (1).

Inspection and Reassembly

1) Clean all components thoroughly, inspect them for any ab-

normality and replace with new ones as necessary.

2) If synchronizer parts (1) need to be repaired, check clearance

“a” between ring and gear, each chamfered tooth of gear (2), ring

(2) and sleeve, then determine parts replacement.

Clearance “a”: Standard 1.0 – 1.4 mm (0.039 – 0.055 in.)

Service limit 0.5 mm (0.019 in.)

3) To ensure lubrication, air blow oil holes (1) and make sure that

they are free from any obstruction.

7A1-18 MANUAL TRANSMISSION

1. Sleeve 2. Hub 3. Key

4. High speed synchronizer spring

4) Fit high speed synchronizer sleeve (1) to hub (2), insert 3 keys

(3) in it and then set springs (4) as illustrated left.

NOTE:

D No specific direction is assigned to high speed synchro-

nizer sleeve or each key but it is assigned as assembly.

D Size of high speed synchronizer sleeve, hub, keys and

springs is between those of low speed and 5th speed

ones.

5) Drive in R bearing (1) to input shaft (2) by using special tool and

hammer.

Special Tool

(A): 09925-98221

6) Install 3rd gear needle bearing, apply oil to it, then install 3rd

gear (1) and synchronizer ring (2).

7) Drive in high speed sleeve & hub assembly (3) by using special

tool and hammer.

NOTE:

D While press-fitting sleeve & hub (3), make sure that syn-

chronizer ring key slots are aligned with keys in sleeve

& hub assembly.

D Check free rotation of 3rd gear (1) after press-fitting

sleeve & hub assembly (3).

D Needle bearings and synchronizer rings for 3rd and 4th

are identical respectively.

Special Tool

(B): 09913-84510

8) Install circlip (1), needle bearing (2), apply oil to bearing, then

install synchronizer ring (3) and 4th gear (4).

CAUTION:

Confirm that circlip (1) is installed in groove securely.

MANUAL TRANSMISSION 7A1-19

9) Press-fit L bearing (1) by using special tool and hammer.

Special Tool

(C): 09925-98221

10) Using the same special tool, drive in 5th gear spacer.

CAUTION:

To prevent 5th gear spacer from being distorted be-

cause of excessive compression, do not press-fit it with

L bearing at once.

COUNTERSHAFT ASSEMBLY

Disassembly

1) Drive out L bearing cone (1) with 4th gear (2) by using puller (3)

and press.

CAUTION:

D Use puller and press that will bear at least 5 ton (11,000

lb) safely.

D To avoid tooth damage, support 4th gear at flat side of

puller.

2) Apply puller (1) to 2nd gear (2) and drive out 3rd & 4th gear

spacer (3) together with 2nd gear (2) by using press. Needle

bearing would come out with 2nd gear (2).

CAUTION:

If compression exceeds 5 ton (11,000 lb), release com-

pression once, reset puller support and then continue

press work again.

3) Take out 2nd synchronizer ring.

4) Using special tool, remove circlip (1).

NOTE:

Correct tool tips to be flat to facilitate removal of circlip.

Special Tool

(A): 09900-06107

7A1-20 MANUAL TRANSMISSION

5) Apply puller (1) to 1st gear (2) and drive out low speed synchro-

nizer sleeve & hub assembly (3) with gear by using press.

6) Disassemble synchronizer sleeve & hub assembly (3).

7) Take out needle bearing from shaft.

8) Remove R bearing cone (1) by using puller (2), metal stick (3)

and press.

Inspection and Reassembly

1) Clean all components thoroughly, inspect them for any ab-

normality and replace with new ones as necessary.

2) If synchronizer parts (1) need to be repaired, check clearance

“a” between ring (1) and gear (2), each chamfered tooth of gear,

ring and sleeve, then determine parts replacement.

Clearance “a”: Standard 1.0 – 1.4 mm (0.039 – 0.055 in.)

Service limit 0.5 mm (0.019 in.)

3) To ensure lubrication, air blow oil holes (1) and make sure that

they are free from any obstruction.

4) Fit low speed synchronizer sleeve (1) to hub (2), insert 3 keys

(3) in it and then set springs (4) as illustrated left.

NOTE:

D No specific direction is assigned to low speed synchro-

nizer hub (2) or each key (3) but it is assigned as assembly.

D Size of low speed synchronizer keys and springs are the

largest compared with those of high speed and 5th speed

ones.

MANUAL TRANSMISSION 7A1-21

2. 1st gear synchronizer ring

A: Align key slots with keys

5. Low speed sleeve & hub assembly

6. 1st gear

5) Install R bearing cone (1) by using special tool and hammer.

Special Tool

(A): 09923-78210

6) Install needle bearing, apply oil to it, then install 1st gear and 1st

gear synchronizer ring (1).

NOTE:

D Key slot width of 1st synchronizer ring is smaller than that

of 2nd synchronizer ring (2).

Distinguish the difference properly.

Width“b”: 8.2 mm (0.32 in.)

“c”: 8.8 mm (0.35 in.)

D Needle bearings for 1st and 2nd gear are identical.

7) Drive in low speed sleeve & hub assembly (1) by using special

tool and hammer.

NOTE:

D Support shaft with special tool as illustrated left so that

retainer of bearing cone (4) will be free from compres-

sion.

D Make sure that synchronizer ring key slots are aligned

with keys while press-fitting sleeve & hub assembly.

D Check free rotation of 1st gear (3) after press-fitting

sleeve & hub assembly.

Special Tools

(A): 09923-78210

(B): 09925-18010

(C): 09940-53111

8) Install circlip (1), needle bearing (2), apply oil to bearing, then

install 2nd gear synchronizer ring (3) and 2nd gear (4).

CAUTION:

Confirm that circlip is installed in groove securely.

7A1-22 MANUAL TRANSMISSION

3. 2nd gear

3. R bearing cone

1. E-ring

2. Washer

3. Low speed select spring

4. Gear shift interlock plate

5. Gear shift & select lever

6. Spring pin (Double)

7. Reverse select spring (Yellow)

8. 5th & REV gear shift cam guide

9. Spring pin

(Apply spring pin remover of

2.8 – 3.0 mm / 0.11 in. diameter)

10. Cam guide return spring

11. 5th & REV gear shift cam

12. Spring pin

13. Gear shift & select shaft

9) Press-fit 3rd gear (1) and spacer (2) by using special tool and

press.

NOTE:

It is recommended to press-fit spacer and 3rd gear first,

and then 4th gear later separately so that countershaft will

not be compressed excessively.

Special Tools

(A): 09923-78210

(D): 09913-80112

10) Press-fit 4th gear (1) by using the same procedure as the

above.

11) Install L bearing cone (2) by using special tool and hammer.

NOTE:

For protection of bearing cone, always support shaft with

special tool as illustrated.

Special Tools

(A): 09923-78210

(E): 09925-98221

GEAR SHIFTER

Gear Shift & Select Shaft Assembly

1) To disassemble component parts, use special tools and 2.8 – 3.0

mm (0.11 in.) pin remover in addition.

Special Tools

(A): 09922-85811 (4.5 mm)

(B): 09925-78210 (6.0 mm)

2) Clean all parts thoroughly, inspect them and replace with new

ones as required.

3) Assemble component parts by reversing removal procedure.

NOTE:

D When driving in spring pins, prevent shaft from being

bent by supporting it with wood block.

D Assemble 5th & REV gear shift cam by winding cam guide

return spring, and then drive in spring pin.

D Locate low speed select spring and reverse select spring

(Yellow-Upper position) correctly.

MANUAL TRANSMISSION 7A1-23

1. Gear shift fork

2. Synchronizer sleeve

1. Reverse gear shift arm

2. Reverse gear shift arm spring (Blue)

3. Steel ball

4. Spring pin

5. 5th & REV gear shift shaft

6. 5th & REV gear shift yoke

7. 5th & REV gear shift guide shaft

A: Face pin slit toward front

High Speed and Low Speed Gear Shift Shafts

Inspection

1) Using feeler gauge, check clearance between fork and sleeve

and replace those parts if it exceeds limit of 1.0 mm (0.039 in.)

NOTE:

For correct judgement of parts replacement, carefully in-

spect contact portion of fork and sleeve.

Clearance “a”: Service limit 1.0 mm (0.039 in.)

2) Insert each gear shift shaft into case and check that it moves

smoothly. If it doesn’t, correct by using oilstone, reamer or the

like.

5th & REV Gear Shifter

1) Disassemble component parts by using special tool and ham-

mer.

Special Tool

(A): 09922-85811 (4.5 mm)

2) Replace or correct parts as required and assemble shafts mak-

ing sure that component parts are in proper order as shown left.

NOTE:

D Distinguish reverse gear shift arm spring (Blue) from low

speed locating spring (Green).

D Install 2 steel balls in reverse gear shift arm without fail.

D Drive in spring pin for reverse shift arm facing slit A to-

ward front.

7A1-24 MANUAL TRANSMISSION

(A)

(B)

1. Differential case

2. Differential gear

3. Differential pinion shaft

1. Screwdriver

2. Differential gear

Left side

DIFFERENTIAL ASSEMBLY

Disassembly

1) Using special tool, remove right bearing (1).

Special Tools

(A): 09913-65810

(B): 09925-88210

2) Remove speedometer drive gear (2).

3) Remove left bearing using puller while supporting its center

shaft as described above.

4) Support differential case with soft jawed vise and remove 8 final

gear bolts then take out final gear.

5) Using special tool and hammer, drive out differential side pinion

shaft pin and then disassemble component parts.

Special Tool

(C): 09922-85811 (4.5 mm)

Adjustment and Reassembly

Judging from abnormality noted before disassembly and what is

found through visual check of component parts after disassembly,

prepare replacing parts and proceed to reassembly. Make sure that

all parts are clean.

1) Assemble differential gear and measure thrust play of differen-

tial gear as follows.

Special Tools

(A): 09900-20606

(B): 09900-20701

Diff. gear thrust play: 0.03 – 0.40 mm (0.002 – 0.013 in.)

Left side

D Hold differential assembly with soft jawed vise and apply mea-

suring tip of dial gauge to top surface of gear.

D Using 2 screwdrivers, move gear up and down and read move-

ment of dial gauge pointer.

MANUAL TRANSMISSION 7A1-25

1. Differential gear

1. Differential side R bearing

2. Speedometer drive gear

3. Differential side pinion shaft pin

4. Differential case

5. Differential side L bearing

Right side

D Using similar procedure to the above, set dial gauge tip to gear

shoulder.

D Move gear up and down by hand and read dial gauge.

2) If thrust play is out of specification, select suitable thrust washer

from among following available size, install it and check again

that specified gear play is obtained.

Available thrust

washer thickness

0.9, 1.0 and 1.1 mm

(0.035, 0.039 and 0.043 in.)

3) Drive in spring pin (3) from right side till it is flush with differential

case surface.

4) Press-fit L bearing by using special tool and copper hammer.

Special Tools

(C): 09913-76010

(D): 09951-16060

5) Install speed sensor rotor (2) drive gear, support differential as-

sembly as illustrated so as to L bearing is floating, and then

press-fit R bearing like L bearing in Step 4).

6) Hold differential assembly with aluminum plates placed on vise,

install final gear and then tighten it with 8 bolts to specified

torque.

CAUTION:

Use of any other bolts than specified ones is prohibited.

Tightening Torque

(a): 90 N

m (9.0 kg-m, 65.0 lb-ft)

7A1-26 MANUAL TRANSMISSION

1. Transmission right case

2. Speedometer driven gear

ASSEMBLING UNIT

DIFFERENTIAL TO LEFT CASE

1) Install differential assembly into right case (1).

2) Insert speedometer driven gear (2) applied with oil to its O-ring,

then tighten it with bolt.

CAUTION:

D While inserting case assembly into transmission, turn

final gear by hand slightly so that gear can mesh easily.

D Never push or hit slit portion of case when inserting it.

Such attempt may cause case to break.

Tightening Torque

(a): 5.5 N

m (0.55 kg-m, 4.0 lb-ft)

3) Join input shaft (1), countershaft (2), low speed gear shift shaft

(3) and high speed gear shift shaft (4) assemblies all together,

then install them into right case (5).

NOTE:

D Input shaft R bearing on shaft can be installed into right

case by tapping shaft with plastic hammer.

D Be careful not to damage input shaft oil seal.

D Check to make sure that counter shaft is engaged with fi-

nal gear while installing.

4) Install 5th & REV gear shift shaft (1) with 5th & REV gear shift

guide shaft (2) into right case (3).

MANUAL TRANSMISSION 7A1-27

A: Thread hole

1. Left case

2. Right case

3. Case bolt

4. Reverse shaft bolt

5) Install reverse gear shift lever (2). Apply thread lock to bolts.

Reverse gear shift arm (5) has to be joined with reverse gear

shift lever (2) at the same time.

Tightening Torque

(a): 23 N

m (2.3 kg-m, 17.0 lb-ft)

6) Make reverse idler gear (1) with reverse gear shift lever (2), in-

sert reverse gear shaft (3) into case (4) through idler gear (1)

and then align A in shaft with B in case.

NOTE:

D Make sure that washer has been installed in shaft at

above the gear.

D Check to confirm that reverse gear shift lever (2) end has

clearance “a” 1 mm (0.04 in.) to idler gear groove.

7) Clean mating surfaces of both right and left cases, coat mating

surface of left case with sealant evenly then mate it with right

case.

Sealant: SUZUKI BOND No.1215, 99000-31110

8) Tighten case bolts from outside to specified torque.

Tightening Torque

(a): 19 N

m (1.9 kg-m, 14.0 lb-ft)

9) Install reverse shaft bolt with aluminum washer and tighten it.

Tightening Torque

(b): 23 N

m (2.3 kg-m, 17.0 lb-ft)

10) Install another 4 case bolts from clutch housing side and tight-

en them to specification.

7A1-28 MANUAL TRANSMISSION

1. Gear shift locating bolt

2. Washer

3. Low speed locating spring (Green)

4. Steel ball

5. High speed locating spring (Green)

6. 5th & REV locating spring (Pink)

11) Check locating spring for deterioration and replace with new

one as necessary.

Locating spring free length

Standard

Service

Limit

5th & REV

(Pink painted)

33.8 mm

(1.331 in.)

32.7 mm

(1.287 in.)

High speed, Low speed

(Green painted)

33.6 mm

(1.323 in.)

32.5 mm

(1.280 in.)

12) Install steel ball and locating spring for respective gear shift

shaft and tighten with bolt.

Tightening Torque

(d): 13 N

m (1.3 kg-m, 9.5 lb-ft)

MANUAL TRANSMISSION 7A1-29

1. Input shaft

1. Straightedge

2. Countershaft

3. Bearing set shim

4. Bearing cup

5. Case surface

6. Feeler gauge

FIFTH GEARS

1) To seat countershaft L bearing cup (2) to bearing cone, tap cup

by using special tool and plastic hammer.

Special Tool

(A): 09913-84510

2) Put a shim on bearing cup provisionally, place straight edge over

it and compress it by hand through straight edge, and then mea-

sure “a” (Clearance between case surface and straight edge) by

using feeler gauge.

Clearance “a”: 0.08 – 0.12 mm (0.0032 – 0.0047 in.)

(Shim protrusion)

3) By repeating above step, select a suitable shim which adjusts

clearance “a” to specification and put it on bearing cup.

NOTE:

Insert 0.1 mm (0.004 in.) feeler to know whether or not a

shim fulfills specification quickly.

Available shim

thickness

0.40, 0.45, 0.50, 0.55, 0.6, 0.65,

0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1.0,

1.05, 1.1 and 1.15 mm

(0.015, 0.017, 0.019, 0.021,

0.023, 0.025, 0.027, 0.029,

0.031, 0.033, 0.035, 0.037,

0.039, 0.041, 0.043 and

0.045 in.)

4) Place left case plate (1) inserting its end in groove of 5th & re-

verse gear shift guide shaft (2) and then tighten it with 5 screws

(3) applied with thread lock cement.

NOTE:

After tightening screws, make sure that counter shaft (4)

can be rotated by hand feeling some load.

“A”: Thread lock cement 99000-32110

Tightening Torque

(a): 9 N

m (0.9 kg-m, 6.5 lb-ft)

7A1-30 MANUAL TRANSMISSION

A: Machined boss (Inside)

B: No machining (Outside)

5) Assemble 5th speed synchronizer sleeve (1) and hub (2) with

keys (3) and springs (4).

NOTE:

Short side C in keys, long boss D in hub and chamfered

spline F in sleeve should face inward (5th gear side).

A = B

C: Short side (Inward)

D: Long boss (Inward)

E: Key way

F: Chamfered spline (Inward)

6) Install countershaft 5th gear (1) to counter shaft facing ma-

chined boss A inward.

7) Apply oil to needle bearing and install it to input shaft.

8) Install input shaft 5th gear to input shaft.

9) Install new counter shaft nut (1) as follows:

a. Shift low speed gear shift shaft (2) to 1st gear position and

high speed gear shift shaft (3) to 3rd gear position.

b. Tighten nut with above double engagement and return shift

shafts to natural position.

Tightening Torque

(a): 70 N

m (7.0 kg-m, 51.0 lb-ft)

MANUAL TRANSMISSION 7A1-31

1, “A”, (a)

A: Oil groove (Align with B)

B: Punch mark (Shows oil hole)

C: Caulking

A: Pin slit (Face outward)

10) Caulk nut at C with caulking tool and hammer.

11) Install synchronizer ring (1).

12) Fit 5th gear shift fork (2) to sleeve & hub assembly (3) and

install them into input shaft, shift shaft and shift guide shaft at

once aligning hub oil groove A with shaft mark B.

NOTE:

Long boss of hub faces inward (gear side).

CAUTION:

Be careful not to pinch synchronizer ring spring by hub.

13) Drive in spring pin facing its slit A outward.

14) Install steel ball, tighten shift fork plug (1) applied with thread

lock cement.

“A”: Thread lock cement 99000-32110

Tightening Torque

(a): 9 N

m (0.9 kg-m, 6.5 lb-ft)

15) Fit hub plate (2) and fix it with circlip.

16) Install circlip (3) to the end of 5th & reverse gear shift guide

shaft.

Make sure circlip is installed in shaft groove securely.

CAUTION:

Coat shift fork plug with thread lock cement reasonably.

If it is done to much, excess may interfere in ball move-

ment and cause hard shift to 5th speed.

17) Clean mating surface of both left case (1) and side cover (2),

coat mating surface with sealant evenly, mate it with left case

and then tighten with 8 bolts.

“B”: Sealant 99000-31110

Tightening Torque for left cover bolts:

(a): 10 N

m (1.0 kg-m, 7.5 lb-ft)

7A1-32 MANUAL TRANSMISSION

1. Gear shift & select shaft assembly

2. Gear shift interlock plate

3. Gear shift yoke

4. Bolt

5. Gear shift interlock bolt

GEAR SHIFT & SELECT SHAFT ASSEMBLY

1) If gear shift guide case (1) has been disassembled or replaced,

tighten bolts as specified below. Also check breather (2) hole

for clog.

Tightening Torque

(a): 10 N

m (1.0 kg-m, 7.5 lb-ft)

(b): 23 N

m (2.3 kg-m, 17.0 lb-ft)

2) Clean mating surface of guide case and coat it with sealant

evenly.

“A”: Sealant 99000-31110

3) Install gear shift yoke (1) and joint it with gear shift arm.

4) Install gear shift & select shaft assembly (2) into transmission

and joint its bottom end with gear shift yoke (1).

NOTE:

When installing gear shift & select shaft assembly (2),

position gear in neutral so that gear shift interlock plate (4)

will go in smoothly.

5) Tighten yoke and shaft with bolt (3) applied with thread lock ce-

ment.

“B”: Thread lock 1322, 99000-32110

Tightening Torque

(a): 34 N

m (3.4 kg-m, 24.5 lb-ft)

6) Install gear shift interlock bolt (5) with washer and tighten it to

specification.

Tightening Torque

(b): 23 N

m (2.3 kg-m, 17.0 lb-ft)

7) Clean mating surface of left case and put gear shift guide case

applied with sealant on it.

Sealant: SUZUKI BOND No.1215, 99000-31110

8) Place wiring harness clamp bracket and fasten it together with

gear shift guide case (1).

Tightening Torque

(a): 10 N

m (1.0 kg-m, 7.5 lb-ft)

9) Install back up light switch (2) and clamp its lead.

Tightening Torque

(b): 20 N

m (2.0 kg-m, 14.5 lb-ft)

10) Clean left case cap and mating surface of left case, check

condition of O-ring and then fasten cap with 3 bolts.

Tightening Torque

(a): 10 N

m (1.0 kg-m, 7.5 lb-ft)

MANUAL TRANSMISSION 7A1-33

11) Check input shaft for rotation in each gear position.

12) Also confirm function of back up light switch in reverse position

by using ohmmeter.

REQUIRED SERVICE MATERIALS

MATERIALS

RECOMMENDED

SUZUKI PRODUCTS

USE

Lithium grease

SUZUKI SUPER GREASE A

(99000-25010)

D Oil seal lips

D Gear shift control lever

D Gear shift control shaft bushes

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 side cover

D Mating surface of gear shift guide case

Thread lock cement

THREAD LOCK 1322

(99000-32110)

D Control lever knob

D Reverse gear shift lever bolts

D Oil gutter bolt

D Left case plate screws

D Gear shift yoke bolt

D Shift fork plug

MANUAL TRANSMISSION 7A1-35

09925-58210

Oil seal installer

09925-68210

Bearing outer race installer

09925-78210

Spring pin remover 6 mm

09925-88210

Bearing puller attachment

09925-98221

Bearing installer

09930-30102

Sliding shaft

09940-53111

Bearing installer

09941-64511

Bearing remover

09951-16060

Bush remover

09951-76010

Bearing installer

Manual Transmission (5-Speed) for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

Related Topics

Popular Owner Manuals

Latest Owner Manuals