shaft SUZUKI SWIFT 2000 1.G Transmission Service User Guide

7A-16 MANUAL TRANSMISSION
TRANSMISSION UNIT
DISMOUNTING
Under Hood
1) Disconnect negative cable at battery.
2) Undo wiring harness clamps, disconnect backup lamp switch
coupler, VSS coupler and ground cable.
3) Disconnect clutch cable from clutch release lever and
bracket.
4) Disconnect gear shift and select control cables.
5) Remove water pipe bracket bolts from transmission.
6) Remove transmission bolts (1).
7) Remove starting motor taking out its bolts.
8) Support engine by using lifting device.
On Lift
9) Drain transmission oil referring to “OIL CHANGE” in this sec-
tion.
10) Remove left and right drive shaft referring to Section 4A.
11) Remove left side of engine under cover.
12) Remove engine rear mounting bracket stiffener (1).
13) Remove clutch housing lower plate.
14) Remove engine rear mounting No.1 bracket (2) with No.2
bracket (3).
15) Remove transfer referring to Section 7D (if equipped).
16) Remove transmission to engine bolt and nut.
17) Lower vehicle and support transmission with transmission
jack.

MANUAL TRANSMISSION 7A-17
18) Remove engine left mounting (1) with bracket (2).
19) Remove other attached parts from transmission, if any.
20) Pull transmission out so as to disconnect input shaft from
clutch disc and then lower it.
REMOUNTING
Remount transmission in reverse order of dismounting procedure
noting the following.
 Refer to Section 7D for installing transfer (if equipped).
 Refer to the first figure of “UNIT REPAIR OVERHAUL” for
fastener specified torque.
 Push in drive shaft joints (right & left) fully so as to snap ring
of shaft engages with differential gear.
 Set each clamp for wiring securely.
 After connecting clutch cable, be sure to adjust its play prop-
erly.
Refer to Section 7C.
 Fill transmission with oil as specified.
 Connect battery and check function of engine, clutch and
transmission.
UNIT DISASSEMBLY
FIFTH GEARS
1) Remove side cover bolts and take off transmission side
cover.
CAUTION:
Care should be taken not to scratch oil seal lip with drive
shaft while raising transmission.
Do not hit drive shaft joint with hammer when installing it
into differential gear.
CAUTION:
Care should be taken not to distort side cover when it is
removed from left case.

7A-18 MANUAL TRANSMISSION
2) Using special tool, remove circlip (1) and then hub plate (2).
Special tool
(A) : 09900-06107
3) If equipped, remove shift fork plug (1) and guide ball (2).
4) Drive out spring pin (3) by using special tool and hammer.
Special tool
(B) : 09922-85811
5) If equipped, remove circlip (4) by using circlip plier.
6) Remove gear shift fork (2), sleeve & hub assembly (3), syn-
chronizer ring spring, synchronizer ring and 5th gear all
together.Use gear puller (1) for removal if spline fitting of hub
is tight.
7) Unfasten caulking of countershaft nut, install input shaft 5th
gear (1) and special tool to stop rotation of shafts, and then
remove countershaft nut (2).
Special tool
(C) : 09927-76010
8) Remove special tool, input shaft 5th gear, needle bearing of
separated steel cage type and then counter shaft 5th gear.
Gear puller (4) would be necessary if spline fitting of counter
shaft 5th gear (3) is tight.
9) Remove plate screws (1) and take off left case plate (2), and
then bearing set shim.
NOTE:
Use of magnet would facilitate removal of guide ball.

MANUAL TRANSMISSION 7A-19
GEAR SHIFTER, INPUT SHAFT AND COUNTER
SHAFT
1) Remove gear shift interlock bolt (1) and 5th to reverse inter-
lock guide bolt (2) from transmission case.
2) Remove gear shifter assembly (3).
3) Remove gear shift locating bolts (1) with washers, then take
out locating springs and steel balls.
4) Remove back up light switch (2).
5) Remove reverse shaft bolt (1) with washer.
6) Remove case bolts (2) from outside and another bolts from
clutch housing side.
7) Tapping left case (3) flanges with plastic hammer, remove
left case.
8) Pull out reverse gear shaft (1) with washer (2), then take off
reverse idler gear (3).
9) Remove reverse gear shift lever bolts (4), and reverse gear
shift lever (5).
10) Pull out 5th & reverse gear shift guide shaft (6) together with
5th & reverse gear shift shaft (7).

7A-20 MANUAL TRANSMISSION
11) Tapping input shaft end with plastic hammer, push it out as
assembly from case a little, then take out input shaft assem-
bly (1), counter shaft assembly (2), high speed gear shift
shaft (3) and low speed gear shift shaft (4) all at once.
12) Remove counter shaft left bearing cup from left case.
13) Remove differential side left oil seal also from left case.
RIGHT CASE
1) Remove differential gear assembly (1) from right case (2).
2) Remove bolt and then pull out VSS (3).
3) If input shaft right bearing has been left in right case, pull it
out by using special tools.
Remove input shaft oil seal (1) by using special tools.
Special tool
(A) : 09930-30104
(B) : 09923-74510
4) Also pull out countershaft right bearing cup (2) by using spe-
cial tools.
Special tool
09941-64511
09923-30104

MANUAL TRANSMISSION 7A-21
SUB ASSEMBLY SERVICE
RIGHT CASE
1) Install input shaft oil seal (1) facing its spring side upward.
Use special tool and hammer for installation and apply
grease to oil seal lip.
“B” : Grease 99000-25010
Special tool
(A) : 09951-76010
2) Install countershaft right bearing cup (2) by using special
tools and hammer.
Special tool
(B) : 09924-74510
(C) : 09925-68210
LEFT CASE
1) If input oil gutter has been removed, install it with bolt to
which thread lock cement have been applied.
“A” : Thread lock cement 99000-32110
Tightening torque
Oil gutter bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
2) Install differential side left oil seal (1) facing its spring side
inward until it becomes flush with case surface by using spe-
cial tool with hammer, and then apply grease to its lip.
“B” : Grease 99000-25010
Special tool
(A) : 09913-75510
3) Install counter shaft left bearing cup into case bore by tap-
ping it with plastic hammer lightly. NOTE:
Before installation, wash each part and apply specified
gear oil to sliding faces of bearing and gear.

7A-22 MANUAL TRANSMISSION
INPUT SHAFT ASSEMBLY
DISASSEMBLY
1) Remove input shaft right bearing (2) from input shaft (1) by
using bearing puller (3) and press.
2) Drive out 5th gear spacer (2), left bearing (3) and 4th gear
(4) all at once from input shaft (1) by using puller (5) and
press.
3) Take out 4th gear needle bearing and high speed synchro-
nizer ring.
4) Using circlip pliers, remove circlip (1).
5) Drive out high speed synchronizer sleeve & hub assembly
(2) together with 3rd gear (3) from input shaft (1) by using
puller (4) and press.
6) Take out 3rd gear needle bearing from shaft.
7) Disassemble synchronizer sleeve & hub assembly.
CAUTION:
To avoid gear tooth from being damaged, support it at flat
side of bearing puller.
CAUTION:
Make sure to use flat side of puller to avoid causing dam-
age to 3rd gear tooth.

MANUAL TRANSMISSION 7A-23
INSPECTION AND REASSEMBLY
1) Clean all components thoroughly, inspect them for any
abnormality and replace with new ones as necessary.
2) If synchronizer parts need to be repaired, check clearance
“a” between ring (2) and gear (1), each chamfered tooth of
gear, ring and sleeve, then determine parts replacement.
Clearance between synchronizer ring and gear
Standard “a” : 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit “a” : 0.5 mm (0.019 in.)
3) To ensure lubrication, air blow oil holes (1) and make sure
that they are free from any obstruction.
4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3
keys (2) in it and then set springs (1) as shown in figure.
Synchronizer key installation position
: A = B
5) Drive in right bearing (1) to input shaft (2) by using special
tool and hammer.
Special tool
(A) : 09913-80112
NOTE:
 No specific direction is assigned to each key but it is
assigned as sleeve & hub assembly.
 Size of high speed synchronizer sleeve, hub, keys and
springs is between those of low speed and 5th speed
ones.
[A] : 3rd gear side
C : Long flange
D : Key way
E : Projecting end

MANUAL TRANSMISSION 7A-25
COUNTER SHAFT ASSEMBLY
DISASSEMBLY
1) Drive out left bearing cone (2) with 4th gear (3) from counter
shaft (1) by using puller (4) and press.
2) Apply puller (5) to 2nd gear (4) and drive out 3rd & 4th gear
spacer (2) and 3rd gear (3) together with 2nd gear from
counter shaft (1) by using press. Take out needle bearing of
separated steel cage type from counter shaft.
3) Take out 2nd synchronizer outer ring, center cone and inner
ring.
4) Using circlip pliers, remove circlip (1).
5) Apply puller (3) to 1st gear (2) and drive out low speed syn-
chronizer sleeve & hub assembly (1) with gear by using
press.
6) Disassemble synchronizer sleeve & hub assembly.
7) Take out needle bearing from shaft.CAUTION:
 Use puller and press that will bear at least 5 ton (11,000
lb) safely.
 To avoid tooth damage, support 4th gear at flat side of
puller.
CAUTION:
 If compression exceeds 5 ton (11,000 lb), release com-
pression once, reset puller support and then continue
press work again.
 To avoid gear tooth from being damaged, support it at
flat side of bearing puller.
CAUTION:
To avoid gear tooth from being damaged, support it at flat
side of bearing puller.

MANUAL TRANSMISSION 7A-27
5) Fit low speed synchronizer sleeve (4) to hub (3), insert 3
keys (2) in it and then set springs (1) as shown in figure.
Synchronizer key installation position
: A = B
6) Install right bearing cone (1) to counter shaft (2) by using
special tool and hammer.
Special tool
(A) : 09923-78210
7) Install needle bearing of resin cage type, apply oil to it, then
install 1st gear and 1st gear synchronizer ring.
8) Drive in low speed sleeve & hub assembly (1) by using spe-
cial tools and hammer, facing “B” side of sleeve to 1st gear.
Special tool
(A) : 09923-78210
(B) : 09925-18011
(C) : 09940-53111 NOTE:
 No specific direction is assigned to each key but it is
assigned as sleeve & hub assembly.
 Size of low speed synchronizer keys and springs are
the largest compared with those of high speed and 5th
speed ones.
[A] : 1st gear side
C : Key way
D : Short flange
NOTE:
 Support shaft with special tool as shown in figure so
that retainer of bearing cone (4) will be free from com-
pression.
 Make sure that synchronizer ring (2) key slots are
aligned with keys while press-fitting sleeve & hub
assembly.
 Check free rotation of 1st gear (3) after press-fitting
sleeve & hub assembly.
A : Align key slots with keys