Suzuki 2006 SX4, Service Manual

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5B-18 Manual Transmission/Transaxle:
Fifth Gear Disassembly and Reassembly
S6RW0C5206015
Disassembly
1) Remove cover bolts and take off transaxle side
cover.
CAUTION
!
Care should be taken not to distort side cover
when it is removed from left case.
2) Using snap ring pliers, remove circlip (1).
3) Remove shift fork shaft bolt (2).
4) Remove gear shift fork (3) and 5th gear all together.
Use gear puller for removal if spline fitting of hub is
tight.
5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and
then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
10. Oil drain plug
: Apply sealant 99000-31260 to all around thread part of plug.
31. Reverse shaft bolt
: Apply sealant 99000-31260 to thread part of bolt.
11. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
32. Washer
12. Left case plate bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
33. Oil seal
: Apply SUZUKI SUPER GREASE A
99000-25010 to Oil seal lip.
13. Side cover bolts 34. Outer race
14. Transaxle case bolts 35. Shim
15. 5th speed synchronizer ring 36. Oil gutter
16. 5th speed synchronizer lever : 21 N
⋅
m (2.1 kgf-m, 15.5 lb-ft)
17. 5th speed sleeve & hub : 23 N
⋅
m (2.3 kgf-m, 17.0 lb-ft)
18. Circlip : 10 N
⋅
m (1.0 kgf-m, 7.5 lb-ft)
19. Bearing set shim : 100 N
⋅
m (10.0 kgf-m, 72.5 lb-ft)
20. Countershaft 5th gear : Do not reuse.
21. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.
: Apply transaxle oil.
3
2
1
I4RH01520015-01
(A)
2
1
I4RH01520016-01
I4RH01520017-01