Suzuki SWIFT RS415 2017, Service Manual

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Manual Transmission: 5B-14
Fifth Gear Disassembly and Assembly
S4RS0A5206018
Disassembly
1) Remove 9 bolts and take off transaxle side cover (1).
CAUTION:
Care should be taken not to distort side cover
when it is removed from left case.
2) Using special tool, remove circlip (1).
Special tool
: 09900–06107
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchronizer levers, synchronizer
ring and input shaft 5th gear (5) 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
1. Transaxle right case 25. 5th gear shift fork
2. Transaxle left case
: Apply sealant 99000-31260 to mating surface of left case and right
case.
26. Needle bearing (Separated steel cage type.)
3. Gear shift and select shaft assembly 27. Input shaft 5th gear
4. Transaxle left case plate 28. Reverse gear shift lever
5. Transaxle side cover
: Apply sealant 99000-31260 to mating surface of side cover and left
case.
29. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
6. Back up lamp switch 30. Reverse gear shaft
7. O-ring 31. Washer
8. Differential assembly 32. Reverse idler gear
9. Oil level/filler plug
: Apply sealant 99000-31260 to all around thread part of plug.
33. Reverse shaft bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
10. Oil drain plug
: Apply sealant 99000-31260 to all around thread part of plug.
34. Washer
11. VSS 35. Side bearing retainer
12. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
36. O-ring
13. Left case plate bolts
: Apply thread lock 99000-32110 to all around thread part of bolt.
37. Oil seal
: Apply grease 99000-25010 to oil seal lip.
14. VSS bolt 38. Outer race
15. Side cover bolts 39. Breather hose
16. Transaxle case bolts 40. Side bearing retainer bolt
17. 5th speed synchronizer ring : 23 N
˜
m (2.3 kg-m, 17.0 lb-ft)
18. 5th speed synchronizer lever : 21 N
˜
m (2.1 kg-m, 15.5 lb-ft)
19. 5th speed synchronizer sleeve & hub : 10 N
˜
m (1.0 kg-m, 7.5 lb-ft)
20. Circlip : 5 N
˜
m (0.5 kg-m, 4.0 lb-ft)
21. Bearing set shim : 100 N
˜
m (10.0 kg-m, 72.5 lb-ft)
22. Countershaft 5th gear : Do not reuse.
23. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.
: Apply transaxle oil.
24. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
I4RS0A520027-
3
4 2
1
5
I4RS0A520028-
1
(A)
2
I3RM0B521014-