SUZUKI GRAND VITARA 1987 Service Repair Manual

10) Remove low gear bush, low speed synchro-
nizer hub, ring, spring, 2nd gear and 2nd
gear bearing by using hydraulic press.
Hydraulic press
Bush
Fig. 13-20
Removing Shift Yokes, Forks and Shafts
412 3 2712 8?
1.
2.
3.
4.
5.
6. 7. Reverse gear shift shaft
8.
Reverse gear shift rim yoke 12.
High speed gear shift shaft
9.
Reverse gear shift fork Low speed gear shift shaft
13.
10.
Low speed gear shift yoke 11.
5th gear shift yoke Low speed gear shift fork
Shift yoke pin High speed gear shift fork
5th select return spring Reverse gear shift rim
spring
E-ring
14.
Fig. 13-21
[Gear shift yokel
For shift yoke removal, drive out yoke pin with
spring pin remover (special tool) first, and then
remove yoke.
Spring pin remover (C) (09922-85811)
Fig. 13-22
[Gear shift fork and shaft]
Before starting removal, make sure that all
shift fork shafts in place are in neutral position and remove each fork and shaft according to
following 1), 2) and 3).
Fig. 13-23 Neutral position1) Pull out reverse gear shift shaft. As this shaft comes out, locating ball and spring
will jump out of hole; do not let them
fly away.
13-10
Fig, 13-24

2) Using the same special tool (C), mentioned
above, drive out yoke pin on high speed
gear shift fork, and pull out shift shaft.
As in above case, be careful not to let
locating ball, interlock ball and spring fly
away.
1 CAUTION:
3) Drive yoke pin out of low speed gear shift
fork as in above step 2) and pull out fork
shaft and fork.
When removing yoke pin, be sure not to
drive it out so far as to contact case. Or it
will cause damage to case.
Fig. 13-27
Fig. 13-25
Fig. 13-28
Fig. 13-26
13-11

13-5. INSPECTION OF COMPONENTS
Gears
Check each part for wear, damage or discolora-
tion. Replace if found defective.
Fig. 13-31
Fig. 13-29
Synchronizer Hubs, Sleeves and Keys
Check each part for wear or damage. Replace if
found defective.
Fig. 13-30
Shift Forks and Sleeves
Check contact surfaces for wear or damage.
Measure clearance between fork and sleeve.
IMaximum clearancej 1.0 mm (0.039 in) 1
Main Shaft
Check each part of shaft for wear, discoloration
or damage. Replace shaft if any part is found
defective.
Fig. 13-32
Bearings and Bushes
Check each part for wear, damage or discolora-
tion. With ball bearing, check to ensure that it
rotates smoothly and it does not make noise.
Replace if found defective.
Fig. 13-33
13-12

Input Shaft
Referring to Fig. 13-34, inspect cone @ and
toothed ring @ for wear and damage.
Inspect gear teeth @I and splines @ for wear
and damage.
If any part of input shaft inspected as above
is found excessively worn or badly damaged,
replace shaft.
Inspect external cone (of gear) and internal
cone (of ring) for abnormal wear. Be sure that
contact patterns on these surfaces indicate
uniform full-face contact, and that surfaces are
free from any wavy wear. A badly worn member
must be replaced.
Proper synchronizing action on gear shifting can
be expected only when ring-to-gear clearance
(Fig. 13-35) and condition of cone surfaces,
among other things, are satisfactory.
Fig. 13-34
Combination of Gear and Synchronizer Ring
Fit ring to cone of each gear, and measure
clearance between the two at peripheral teeth,
as shown in Fig. 13-35. If clearance exceeds
service limit, replacement is necessary.
IClearance between gear and ringI
IIStandard( Service limit 1
~fJ l.O-1.4mm 1 iI;n.j 1
(0.039 - 0.055 in.)
5th speed1.2- 1.6mm0.5 mm
(0.047 - 0.063 in.)(0.019 in.)I
Fig. 13-36 @I Checking con tacting surface
Chamfered Tooth Ends of Ring (External
Teeth) and Sleeve (Internal Teeth)
Synchronizer ring and hub have three slots each,
in which keysare carried as backed by expanding
springs, so that the hub and its two rings, one
on each end, are capable of running together.
Since the sleeve is engaged by its internal teeth
with the hub as if the two were splined together,
the sleeve, too, runs with the hub and rings.
In meshing action, the sleeve is pushed (by the
shifter fork) to one side, so that if slides axially
on the hub, pushing the ring toward the cone
surface of the gear. This push is transmitted by
three keys, which are lightly gripped by the
sleeve.
Fig. 13-35
13-13

By friction between the gear cone and ring
cone (internal), the ring begins to rotate but
is copposed by the hub because of keys. In
other words, the ring is at this time twisted,
while the sleeve is advancing further to push the
ring fully against the gear cone, Since the
ring is unable to slide along any further, the
sleeve lets go off the keys and rides over to the
ring. At this moment, the initial contact be-
tween the chamfered ends of teeth of the ring
and those of internal teeth of the sleeve occurs.
This contact is such that the internal teeth of
the sleeve align themselves to those of the ring.
When the sleeve advances and slides into the
ring, the ring will be rotating nearly with the
speed of the gear, so that the sleeve is enabled
smoothly to slide over into the clutch teeth of
the gear.
The initial contactor mesh between sleeve and
ring is determined by the widths of key and slot
or, in other words, the key clearance in the
slot, and is prescribed to extend at least a
third (l/3) of the chamfer.
With the synchronizer properly assembled on
the shaft, push in and twist each synchronizer to
see if one-third mesh occurs or not; if not, it
means that the overall wear (which is the sum of
wears of slots, keys and chamfered tooth ends)
is excessive and, in such a case, the entire
synchronizer assembly must be replaced.
1Mesh of chamfered toothContact extending
ends of synchronizer ringabout l/3 of cham-
and sleevefered face from apex
l/3
Synchronizer Rings
Inspect each synchronizer ring for wear of its
key slots by measuring width of each slot.
If width reading exceeds limit, replace ring.
Key slot width
of synchronizer
ring
Fig. 73-38
Fork Shaft Locating Springs
If “gears slipping out of mesh” has been com-
plained, check these springs for strength by
measuring their free length, and replace them if
their free lengths are less than service limit.
Spring No.
Free length
StandardService limit
25.5 mm21.0 mm
(I.004 in.)(0.826 in.)
Fig. 73-39
13-14

Gear Shift Shafts
Check the part of shaft as indicated in below
figure for uneven wear. Replace shaft if uneven
wear is noted.
Fig. 13-40
Extension Case Bush
Check bush press-fitted in extension case for
wear by measuring radial clearance between
bush bore and sliding yoke. If sliding yoke
rattles in bush because of advanced wear it will
cause propeller shaft to rattle. For this reason,
an extension case found to allow its sliding
yoke to rattle in excess of service limit must be
replaced; replacement of bush alone is not
permissible.
Rattle of
sliding yoke
c
in extension
case bush Standard
1 Service limit
0.025
- 0.089 mm 0.2 mm
(0.0010
- 0.0035 in.) (0.0078 in.)
III
13-6. IMPORTANT STEPS IN
INSTALLATION
NOTE:
l Before installation, wash each part and apply
specified gear oil to sliding faces of bearing
and gear.
l Use new circlips on shaft for reinstallation.
Don’t reuse used circlips.
l Tighten each fastening bolt and nut according
to specified torque data listed on the last
page of this section.
Main Shaft and Input Shaft:,
Install each parts by reversing respective removal
procedures. Be careful for installing direction of
each washer, gear, synchronizer hub and sleeve.
Refer to figure below. Make sure to install each
ball on main shaft.
5 17la 1.11616
1. High speed synchronizer
hub2. High speed synchronizer
sleeve
3.3rdgear
4.2ndgear
5. Low speed synchronizer
hub6. Low speed synchronizer
sleeve
7.Lowgear
6.Washer
9.Ball10.Reverse gear11. Reverse synchronizer
hub
12.Reverse synchronizer
sleeve13.5th gear14. 5th gear washer
15. Circlip
16.
Main shaft17.Spring
Fig. 13-4 1
13-15

1) Install 2nd gear bearing, 2nd gear, spring,
synchronizer ring and low speed synchroni-
zer hub/sleeve onto main shaft, using care
for installing direction of synchronizer
sleeve.
After putting on each synchronizer, be sure
that 3 keys mounted on hub fit snugly into
slots cut inring.
Fig. 13-42
Then using hydraulic press, press-fit low gear
bush. 2 bushes on main shaft are the same.
Bearing installer (D)(09925-18010)
Fig. 13-43
2) Install low gear needle bearing, spring,
synchronizer ring, low gear, ball and washer
onto main shaft.
Fit ball into hole in shaft and install washer
so that its slot @ comes over ball 0.
To direct washer correctly, bring its circum-
pherence chamfered side @ to main shaft
center bearing.
Fig. 13-44
3) Press-fit center bearing with bearing installer
(special tool) using care for its installing
direction.
Bearing installer (D) (09925-18010)
(D)
Ring groove
-
Fig. 13-45
4) Install ball and washer.
As figure shows, install washer so that its
circumfherence chamfered side faces center
bearing @and its slot @ comes over ball 0.
Washer\Washer
c3RearbaarinBside
d
Fig. 13-46
13-16

5) Press-fit reverse gear bush, preventing ballinstalled in step 4) from
coming off.
Bearing installer (D) (09925-l 8010)
6) Install reverse gear bearing, reverse gear and
reverse synchronizer hub/sleeve. For proper
direction, make sure to install hub so that
the side whose inside boss
@ is smaller in
diameter and longer is directed to main
shaft rear bearing, and sleeve so that the side whose inside is stepped
@ is also directed to
main shaft rear bearing.
Sleeve
Main shaft
rear bearing
side
H;b
Fig. 13-48 7) Fit reverse hub circlip into groove in main
shaft.
Fig. 13-50
8) Install 5th gear bearing, 5th gear synchroni-
zer ring and 5th gear. Then install ball and
washer, making oil groove of washer face 5th
gear.
Fig. 13-51
9) Press-fit main shaft rear bearing and fit
circlip into groove in main shaft.
Bearing installer
(D)(09925-18010)
Fig. 1349Fig. 13-52
13-17

Fig. 13-53
10) Install 3rd gear bearing, 3rd gear, high speed
synchronizer ring and hub/sleeve. When
installing hub, direct the side with larger
outer diameter boss to 3rd gear side. Then
fit circlip into groove in main shaft.
3rd earB
H’ub
Fig. 13-54
Fig. 13-55
11) Install synchronizer ring, needle bearing and
input shaft.
Fig. 13-56
Counter Shaft and Reverse Idle Gear
1) Drive counter shaft front bearing into lower
case. Then using plastic hammer, drive
counter shaft into front bearing a little.
In the above state, using bearing installer
(special tool), drive center bearing onto
counter shaft and into lower case.
Bearing installer (D) (09925-18010)
1. Center bearing
2. Counter shaft
Fig. 13-57
3. Transmission lower case
4. Wood stand
13-18

2) Fit counter shaft front circlip into groove in
shaft.
Fig. 13-60
Fig. 13-58
3) Install counter shaft reverse gear and 5th
gear onto counter shaft. And then drive
counter shaft rear bearing onto it.
Fig. 13-61
Fig. 13-59
4) Install idle gear and washer onto reverse
gear shaft and pin into it.
Install above as assembled into lower case
with pin (ij and washer tongue @ aligned as
shown below.
Shifter Forks, Shafts and Yokes
[Forks and Shafts]
Fig. 13-621
8
Low speed gar shift shaft
2High speed gear shift shaft
@ Reverse gear shift shaft
13-19