Countershaft and Reverse Idle Gear Inspection

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.

Using micrometer, check diameter of countershaft as shown. If measured valve is out of specification, replace it.
Countershaft diameter-(standard)

"a": 25.986 - 26.000 mm (1.0231 - 1.0236 in.)

"b": 30.957 - 30.972 mm (1.2188 - 1.2194 in.)

Fig 1: Checking Diameter Of Countershaft
Courtesy of SUZUKI OF AMERICA CORP.
Check clearance between fork and sleeve. If clearance exceeds limit, replace fork and sleeve.
Clearance between fork and sleeve

Standard: 0.15 - 0.35 mm (0.006 - 0.014 in.)

Limit: 1.0 mm (0.039 in.)

Fig 2: Checking Clearance Between Fork And Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Check clearance "a" between synchronizer ring and gear, key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Clearance "a" between synchronizer ring and gear (countershaft)

Standard: 1.0 - 2.0 mm (0.039 - 0.079 in.)

Limit: 0.8 mm (0.031 in.)

Key slot width "b" (countershaft)

Standard: 10.0 - 10.2 mm (0.394 - 0.402 in.)

Limit: 10.45 mm (0.411 in.)

Fig 3: Checking Clearance Between Synchronizer Ring And Gear
Courtesy of SUZUKI OF AMERICA CORP.
Using cylinder gauge (1), check inside diameter of countershaft 5th gear (2). If measured value exceeds specification, replace gear.
Countershaft 5th gear diameter

Standard: 33.015 - 33.040 mm (1.2998 - 1.3008 in.)

Fig 4: Checking Inside Diameter Of Countershaft 5th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Check oil clearance between reverse idle gear (2) and shaft (1) by measuring inside diameter of gear and diameter of shaft and calculate its clearance. If clearance exceeds limit, replace gear and shaft.
Oil clearance between reverse idle gear and shaft

Standard: 0.040 - 0.082 mm (0.0016 - 0.0032 in.)

Limit: 0.13 mm (0.005 in.)

Fig 5: Checking Oil Clearance Between Reverse Idle Gear & Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Check clearance between reverse idle gear (2) and shoe (1) of reverse gear shift link. If clearance exceeds limit, replace shoe.
Clearance between reverse idle gear and shoe

Standard: 0.05 mm - 0.28 mm (0.002 - 0.011 in.)

Limit: 0.5 mm (0.020 in.)

Fig 6: Checking Clearance Between Reverse Idle Gear & Reverse Gear Shift Link Shoe
Courtesy of SUZUKI OF AMERICA CORP.