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

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.

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

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