Suzuki SWIFT 2005 User Manual

5B-14 Manual Transmission/Transaxle:
Fifth Gear Disassembly and Assembly
S7RS0B5206014
Disassembly
1) Remove cover bolts and take off transaxle side cover
(1).
CAUTION
!
Care should be taken not to distort side cover
when it is removed from left case.
2) Using snap ring pliers, remove circlip (1).
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchronizer levers, synchronizer
ring and input shaft 5th gear (5) all together. Use
gear puller for removal if spline fitting of hub is tight.
5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and
then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
11. Sensor cap 34. Washer
12. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
35. Side bearing retainer
13. Left case plate bolts
: Apply thread lock 99000-32110 to all around thread part of bolt.
36. O-ring
14. Sensor cap bolt 37. Oil seal
: Apply grease 99000-25011 to oil seal lip.
15. Side cover bolts 38. Outer race
16. Transaxle case bolts 39. Breather hose
17. 5th speed synchronizer ring 40. Side bearing retainer bolt
18. 5th speed synchronizer lever : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
19. 5th speed synchronizer sleeve & hub : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
20. Circlip :10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
21. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
22. Countershaft 5th gear : Do not reuse.
23. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.
: Apply transaxle oil.
I4RS0A520027-01
3
4
2
1
5
I4RS0A520028-01
1
(A)
2
I3RM0B521014-01
I4RS0A520041-01

Suzuki SWIFT 2005 Specifications

General

Brand	Suzuki
Model	SWIFT 2005
Category	Automobile
Language	English