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

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).

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

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