Locating Spring Inspection; Input Shaft Disassembly; Input Shaft Inspection - Suzuki Grand Vitara 2011 Manual

5B-23 Manual Transmission/Transaxle: For Petrol Engine Model

Locating Spring Inspection

Check locating springs for deterioration and replace with
new ones if necessary.
Locating spring free length
Standard: 44.6 mm (1.756 in.)
Service limit: 40.1 mm (1.579 in.)

Input Shaft Disassembly

1) Remove snap ring.
2) Remove input shaft front bearing (1) using bearing
puller and hydraulic press.
3) Remove input shaft union.
4) Hold hatched area (5) of input shaft assembly (1)
with "V" blocks (4) on vise (2) or the like to stop
rotation of shaft, undo caulking and input shaft 5th
hub nut (3).
CAUTION
!
Do not hold spline, gear teeth or abrasived
surface of shaft with vise through "V" blocks
or the like, otherwise shaft components may
be damaged.
1
2
4
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5
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5) Apply bearing puller to 4th gear (1), and drive out 5th
speed synchronizer hub (2), 3rd gear (3), high speed
gear needle bearings, 3rd gear bush, high speed
synchronizer assembly (4) and 4th gear all at once
from input shaft using metal stick (5) and press.
CAUTION
!
To avoid gear teeth from being damaged,
support 4th gear at flat side of bearing puller.
5
4

Input Shaft Inspection

• Check clearance "a" between synchronizer ring (2)
and gear (1), 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 (Input shaft) (3rd and 4th)
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width "b" (3rd and 4th synchronizer ring)
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)
2
3
1
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