Countershaft and Reverse Idle Gear Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Fit sleeve (4) to countershaft 5th gear (3), place 3 synchronizer keys (2) in it and then set synchronizer springs (1).
Refer to figure for proper installing direction of gear, sleeve and springs. Also, note that key has specific installing direction.

Fig 1: Fitting Sleeve To Countershaft 5th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Set inner race (2) to countershaft front bearing (1) and press-fit bearing with hydraulic press and special tool.
NOTE: When installing bearing, bring it so that its groove for circlip is in the front.

Special tool

(A): 09940-54950

Fig 2: Setting Inner Race To Countershaft Front Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Select circlip that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it.

Fig 3: Circlip Thickness Specifications Chart
Courtesy of SUZUKI OF AMERICA CORP.

Special tool

(B): 09900-06107

Fig 4: Selecting Circlip
Courtesy of SUZUKI OF AMERICA CORP.