Suzuki RA410, Manual

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2) Apply puller (1) to 2nd gear (2) and drive out 3rd gear (3) and
3rd & 4th gear spacer (4) 2nd gear using press. Needle bearing
would come out with 2nd gear.
CAUTION:
If compression exceeds 5 ton (11,000 lb), release com-
pression once, reset puller support and then continue
press work again.
4
3
2
1
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
2. Low speed
synchronizer
sleeve
2
1
5) Apply puller (1) to 1st gear (2) and drive out low speed synchro-
nizer sleeve & hub assembly (3) with gear using press.
6) Disassemble synchronizer sleeve & hub assembly.
7) Take out needle bearing from shaft.
3
2
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 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.)
2
1
3) To ensure lubrication, air blow oil holes (1) and make sure that
they are free from any obstruction.
1
MANUAL TRANSMISSION 7A-21