Manual Transmission Upper Case & Shifter Inspection

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Check for the following items

Using feeler gauge, check clearance between fork (2) and sleeve (1) and replace those parts if it exceeds limit of 1.0 mm (0.039 in.).
Clearance "c" between sleeve and fork
1. Limit: 1.0 mm (0.039 in.)
Fig 1: Identifying Clearance Between Shift Fork & Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Insert each gear shift shaft into case and check that it moves smoothly. If it doesn't, correct by using oilstone, reamer or the like.
Check gear shift shaft for excessive wear and correct or replace a necessary.

Fig 2: Identifying Shift Fork Locating Grooves & Shift Fork Yokes
Courtesy of SUZUKI OF AMERICA CORP.
Check free length of each locating spring (1) and replace if it is below service limit.
Locating spring free length "b"

Standard: 27.0 mm (1.063 in.)

Limit: 24.0 mm (0.945 in.)

Fig 3: Checking Free Length Of Locating Spring
Courtesy of SUZUKI OF AMERICA CORP.