Suzuki SY419, Supplementary Service Manual, Page: 141 / 240

MANUAL TRANSMISSION 7A-1
SECTION 7A
MANUAL TRANSMISSION
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “System Components and Wiring Location View” under “Gen-
eral Description” in air bag system section in order to confirm whether you are performing service
on or near the air bag system components or wiring. Please observe all WARNINGS and “Precau-
tions” in air bag system section before performing service on or around the air bag system compo-
nents or wiring. Failure to follow WARNINGS could result in unintentional activation of the system
or could render the system inoperative. Either of these two conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to
the “LOCK” position and the negative cable is disconnected from the battery. Otherwise, the sys-
tem may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
GENERAL DESCRIPTION 7A- 2 . . . . . . . . . . . . . .
DIAGNOSIS 7A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 7A- 6 . . . . . . . . . . . . . . . .
Oil Charge 7A- 6 . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Side Oil Seal 7A- 7 . . . . . . . . . . . . . .
Gear Shift Control 7A- 9 . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL 7A-11 . . . . . . . . . . . . . .
Dismounting of Transmission 7A-11 . . . . . . . . . .
Remounting 7A-12 . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling Unit 7A-12 . . . . . . . . . . . . . . . . . . .
Fifth gears 7A-12 . . . . . . . . . . . . . . . . . . . . . . . .
Gear shifter 7A-13 . . . . . . . . . . . . . . . . . . . . . . .
Main shaft and countershaft 7A-13 . . . . . . . . .
Right case 7A-14 . . . . . . . . . . . . . . . . . . . . . . . .
Sub Assembly Service 7A-15 . . . . . . . . . . . . . . . .
Right case 7A-15 . . . . . . . . . . . . . . . . . . . . . . . .
Gear shifter 7A-16 . . . . . . . . . . . . . . . . . . . . . . .
Differential assembly 7A-16 . . . . . . . . . . . . . . .
Assembling Unit 7A-19 . . . . . . . . . . . . . . . . . . . . .
Differential to left case 7A-19 . . . . . . . . . . . . . .
Gear shift and select shaft assembly 7A-21 .
TIGHTENING TORQUE SPECIFICATIONS 7A-22
REQUIRED SERVICE MATERIALS 7A-22 . . . . . .
SPECIAL TOOLS 7A-23 . . . . . . . . . . . . . . . . . . . . . .
7A