DIY suzuki liana manual transmission repair

Specifications, 5-Speed ​​012

Do not lubricate the gear lever linkage.

GEAR LEVER LEVER, ADJUSTMENT / CHECK

Installation is carried out in the reverse order of removal.

Please note the following when installing:

- check that the centering sleeves are installed correctly.
- install the clutch slave cylinder in place using the lever so that the bolt can be inserted easily. Warning

The bolt for the clutch slave cylinder has a pointed end to facilitate installation.

Tightening torques for screw connections

FIXING THE TRANSMISSION TO THE ENGINE

1 = bolt M12 x 70
2 = bolt M12 x 85
3 = bolt M12 x 100
4 = bolt M8 x 15

1 = bolt M12 x 70
2 = bolt M12 x 80
3 = bolt M12 x 90
4 = bolt M12 x 100
5 = bolt M11 x 120
6 = bolt M10 x 50
7 = bolt M10 x 40
8 = bolt M8 x 40

Location of centering sleeves: points A and B

Location of centering sleeves: points A and B

If you need to replace the final drive housing or the tapered roller bearing of the pinion gear or hollow shaft and the deviation r is not indicated on the bevel gear, the installation position of the pinion gear must be determined before removing the gearbox housing (it is necessary to measure the actual deviation).

Before installing the transmission case, check that the guide bushings are installed in the transmission case.

Handle the transmitting device of the speedometer very carefully. Do not drop it, otherwise the speedometer reading may be inaccurate.

Final drive mechanism

The speedometer drive1 can be replaced without removing the gearbox.

Differential 2 can be removed without removing the gearbox housing.

Remove O-ring 3 using VW tool 681.

Seal the final drive cover 4 with AMV 188 200 03.

Always replace circlips 6 and 23.

Install the drive shaft flange using VW tool 295.

The side of the concave washer 10 with a smaller diameter faces the guide sleeve (concave side).

Mark the retaining rings 11, 13 after removal.

Drive shaft flange O-ring - Remove with VW tool 681 and install (5mm below the surface of the final drive housing) with tool VW 195.

Final drive housing 15: Drive shaft flange O-ring - remove with VW tool 681. Install (5 mm below the surface of the final drive housing) with tool VW 195. 3rd / 4th gear shift rod bushing - install with tools VW 295 and VW 295А. Seal with AMV 188 200 03.

Gear lever channel cover 18 - tighten the mounting bolt to 20 N.m.

The lock for 5th gear and reverse gear 22 can be replaced without removing the gearbox. The beveled side of the plastic bushing faces the shift shaft. Tightening torque for the mounting bolts: 10 N.m.

1. Internal shift rod
2. Shift rod of 1st, 2nd, 5th gear and reverse gear with a shift fork
3. Hollow shaft drive gear
4. Transmission housing
5. Socket head bolt - 25 N.m.
6. Socket head bolt for reverse gear axis - 35 N.m.
7. Socket head bolt - 25 N.m.
8. Lock
9. Socket head bolt - 40 N.m.
10. Washer
11. Shifting shaft

Remove the O-ring of the inner shift rod 1 using the VW 681 tool and install it flush with the VW 460/2 tool. On the installed gearbox, carefully remove the O-ring with a screwdriver and install with the VW 423 tool. First, remove the exhaust pipes and the shift rod gear to get free space.

1st, 2nd, 5th and reverse gear shift rod with shift fork 2 - for disassembly / assembly, remove / install spring pins. 1st / 2nd gear shift forks can be replaced individually. Replace the 5th / reverse shift fork only with the shift ring and shift rod.

Socket head bolt for reverse gear axle 6 - 35 N.m. The reverse gear axle does not need to be removed to remove the reverse gear.

Socket head bolt 7-25 N.m. The inside of the head faces the spring / lock safety mechanism.

Install the lock 8 after installing the selector shaft 11 and the inner selector rod.

3rd / 4th gear shift rod and shift fork: The shift rod or shift fork can be individually replaced. Replace the shift rod bearing if worn.

Removing the shift shaft bolts

professional repair with a quality guarantee of mechanical gearboxes of the car of the Suzuki Liana brand of all modifications 1.3 1.6 Moscow Russian Federation

Gearbox REPAIR SUZUKI Liana 1.3 1.6
MEKHANINDIVIDUAL GEARBOXES SUZUKI Liana
installation replacement buy all modifications 1.3 1.6
repair and restoration of shafts argon welding of the manual transmission body
Moscow city

Artem 8 965 126 13 83 Vadim 8 925 675 78 75

Full car diagnostics during repair - free of charge!

Possessing a high level of professionalism, extensive experience in the repair of manual transmissions, and our own warehouse of spare parts, we carry out diagnostics, sale, replacement and repair of all types of manual transmissions for the SUZUKI Liana car. Box repair starts with an initial, obligatory free diagnostics.

• consulting by a repairman / by phone free of charge /
• delivery of the car for repair / within the city of Moscow 3,000 rubles. From the Moscow region and other regions of the Russian Federation - by agreement /
• complex car diagnostics / determination of the presence of a malfunction of the engine, manual transmission, ABS, brake system; checking the electrical circuits of the car for corrosion, checking the kinematic destruction of the unit, checking the level of transmission oil, checking the operability of the hydraulic clutch system / - during repairs free of charge
• visual inspection, checking the integrity of the hull
• checking the transmission oil content for steel, aluminum or bronze chips
• opening the pallet / if necessary /
• removal from the car
• disassembly, flushing of parts and assemblies
• troubleshooting / presence of the car owner - required /
• agreement with the car owner on the cost of full repair and the date of completion of the repair
• receipt of spare parts from the warehouse / rem. kit, consumables, units /
• repair / argon welding / gearbox housing if necessary
• assembly
• clutch replacement / at the request of the car owner /
• installation on a car
• filling with gear oil
• output diagnostics and tested drive of the car

Warranty from 3 to 24 months or 60,000 km. mileage.

We have a fund restored manual transmissions SUZUKI Liana 1.3 1.6 / see article replacement / ... If the car owner wishes, we can replace the faulty one with one that has been sorted out from the exchange fund, which is often more economically feasible.

Complex troubleshooting of manual transmission (disassembly - assembly) without repair

Removal and installation (as separate work)

Replacing the clutch with the box removed

• economy - from 3,000 to 8,000 rubles / use, at the request of the car owner, only used parts to reduce the cost of repairs /
• business - from 8,000 to 28,000 rubles. / replacement only of directly damaged parts in the unit /
• representative - from 28,000 to 60,000 rubles/ replacement regardless of damage with a set: oil seals, bearing bearings, needle bearings, synchronizers, stoppers, coupling hub locks - plus directly affected parts /

Own warehouse of spare parts necessary for the repair of manual transmissions. Bearings, oil seals, gears, synchronizers, gear couplings, shafts, differentials, manual transmission housings are available and on order for all brands of cars.

• replacement and repair of transmission SUZUKI Liana
• replacement and repair of SUZUKI Liana manual transmission
• replacement and repair of the SUZUKI Liana gearbox
• replacement of transmission oil SUZUKI Liana
• clutch replacement SUZUKI Liana
• replacement release bearing SUZUKI Liana
• replacement of the rear oil seal and crankshaft bearing SUZUKI Liana
• replacement of the input shaft oil seal and drive oil seals SUZUKI Liana
• replacement of the input shaft of the SUZUKI Liana manual transmission
• replacement of the secondary shaft of the SUZUKI Liana manual transmission
• backstage repair of the SUZUKI Liana checkpoint
• repair (argon welding) of the SUZUKI Liana manual transmission case
• repair of the secondary shaft of the SUZUKI Liana gearbox
• replacement of the fifth gear of the manual transmission (without removing the gearbox from the car) SUZUKI Liana
• repair of 1st and 2nd gear SUZUKI Liana
• repair of 3rd and 4th gear SUZUKI Liana
• repair of 5 gear SUZUKI Liana
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• buy gearbox SUZUKI Liana

Call us to choose a time for manual transmission diagnostics and repairs in a gearbox repair workshop. An appointment in advance will allow you to find the most convenient solution, we are always ready to meet the wishes of the client.

Our specialized repair shops for manual transmission SUZUKI Liana gearboxes provide high-quality service, diagnostics and repair of all types of gearboxes. We offer an honest service for your repair. Your presence is mandatory at all stages of diagnostics and repair of the SUZUKI Liana gearbox; all work and accessories are coordinated. The term for overhaul of the gearbox is from 0.5 to 1 working days (if the necessary parts are available).

We have round-the-clock line consultations on the repair of manual transmissions of gearboxes (8 965 126 13 83) and delivery for repair on a tow truck (8 926 167 15 40). A tow truck for manual transmission repairs is provided for a fee (within the MKAD - 3000, outside the MKAD by agreement).

The cost of work during the overhaul of the SUZUKI Liana gearbox is 10,000 rubles (input and output diagnostics, removal and installation of the gearbox, disassembly and assembly, weekend test drive) + cost of components.

Input diagnostics is carried out with the obligatory presence of the owner of the car within 30 - 40 minutes after removing the gearbox from the car (inspection, disassembling the manual gearbox, flushing the inner case of the gearbox from metal shavings, disassembling the shafts).

Removal of the gearbox from the car, disassembly and troubleshooting takes place on the day of the request for repair.

The warranty for the repair of the gearbox of the SUZUKI Liana gearbox is from 1 to 12 months or 60,000 km of run (set individually for each car - depending on the components during the repair).

Rice. 3.63. Removing the plate from the drive shaft

Unscrew the bolts of the left housing plate 1, and remove the plate 2 (Fig. 3.63).

Remove the bearing shim.

Remove the retaining ring 1 using a special tool (Fig. 3.64).

Unscrew the bolts of the clamps 1, then take out the springs and steel balls (Fig. 3.65).

Remove the reversing light switch.

Remove the reverse shaft bolt 2 with a washer.

Rice. 3.66. Main drive and reverse shaft housing bolts

Remove the bolts of the main gear case 1 from the outside, and the rest of the bolts from the side of the clutch case (Fig. 3.66).

Remove the left casing by tapping with a plastic hammer on the casing tabs.

Take out the reverse gear shaft 1 with washer 2, then remove the intermediate reverse gear 3.

Unscrew the bolts of the reverse gear lever 4 and remove the reverse gear lever 5.

Rice. 3.67. Reverse gear components

Remove the 5th gear shift guide and reverse gear 6 together with the 5th gear shift shaft and reverse gear 7 (Fig. 3.67).

When removing the shift shaft for 5th gear and reverse gear 7 and guide 6, lift the shift shaft for high gears and set it to the position corresponding to the inclusion of 4th gear, so that it is easier to remove the shift shaft of the 5th gear and reverse gear.

Rice. 3.68. Removing the drive shaft, intermediate shaft and high gear shift shaft

Applying light blows with a plastic hammer to the end of the drive shaft, slightly push it out of the housing assembly, then remove the drive shaft 1, the intermediate shaft 2, the high gear shift shaft 3 and the low gear shift shaft 4 at the same time (Fig. 3.68).

Remove the left intermediate shaft bearing outer race from the housing.

Remove the differential from the right-hand housing (for two-wheel drive vehicles).

Remove the side bearing cover as follows (for two-wheel drive vehicles).

Remove the bearing assembly side cover bolts.

Rice. 3.69. Removing the side cover of the bearing assembly

Turn the side cover of the bearing unit 1 counterclockwise until it stops and remove the cover using 2 mounting blades (Fig. 3.69).

Rice. 3.70. Removing the outer ring of the differential bearing from the left housing

Remove the outer ring of the differential bearing from the left housing using a special tool (Fig. 3.70).

Rice. 3.71. Installing the drive shaft, intermediate shaft and high gear shift shaft

Assemble together the drive shaft 5, the intermediate shaft 4, the low gear shift shaft 2 and the high gear shift shaft 3, and then install them in the right housing 1 so as not to damage the oil seal with the drive shaft splines (Fig. 3.71).

The right bearing of the drive shaft can be installed in the right housing 1 with a plastic hammer.

When installing, make sure that the intermediate shaft meshes with the final drive.

Rice. 3.72. Installing the shift shaft for 5th gear and reverse gear from the guide for shifting 5th gear and reverse gear into the right housing

Install the shift shaft of the 5th gear and reverse gear 1 with the guide for switching the 5th gear and reverse gear 2 into the right case 5. The reverse gear shift lever 4 must be attached to the lever 3 (Fig. 3.72).

Rice. 3.73. Installing the reverse idler gear

Install the reverse idler gear 1 with the reverse gear lever 2, install the reverse gear shaft 3 into the right case 4 through the hole in the idler gear, then align “A” on the shaft with “B” in the case (Fig. 3.73).

Make sure washer 5 was installed on the shaft above the gear.

Make sure there is a gap “a” between the end of the reverse gear lever and the idler shaft.

Distance between the end of the lever and the idler shaft “a”: 0.5–1.0 mm.

Tighten the reverse gear lever bolts after applying thread sealant to the threads.

Reverse gear lever bolt tightening torque: 23 Nm.

Install the differential in the right-hand housing (for two-wheel drive vehicles).

Rice. 3.74. Differential Housings Coupling

Clean the mating surfaces of the right and left cases and evenly cover the mating surface of the left case 1 with sealant, then connect the left case to the right 2 (Fig. 3.74).

Tighten the body bolts 3 from the outside to the nominal tightening torque.

Tightening torque for final drive housing bolt (b): 23 Nm.

Install the reverse shaft bolt 4, covering its threaded part with sealant, with an aluminum washer and tighten it.

Reverse shaft bolt tightening torque (c): 23 Nm.

Install the remaining body bolts from the clutch housing side and tighten.

Tightening torque of the final drive housing bolt: 23 Nm.

Install the side bearing cover as follows (for two-wheel drive vehicles).

Rice. 3.75. Installing the outer ring of the differential bearing

Install the outer ring of the differential bearing in the left housing and press it in using a special tool and a plastic hammer (Fig. 3.75).

Do not hit the ring with a hammer. This could damage the bearing.

Fit the differential bearing shim as follows.

Rice. 3.76. Differential bearing shim selection diagram

Measure the distance "a" from the back surface of the left housing 1 to the outer ring of the bearing 2 with a depth gauge (Fig. 3.76).

Measure the height "b" of the side bearing cap with a depth gauge.

Calculate the clearance "a" - "b" and select the shim according to the following table.

Install the differential bearing shim in the left housing 3.

Rice. 3.77. Installing the differential bearing spacer

Apply oil to a new O-ring of the side bearing cover 2 and install the bearing cover with a ring in the left housing 3 (Fig. 3.77).

Tighten the bearing cap bolts 1 to the rated torque.

Install the bearing cover with mark 4 facing up.

Tightening torque for bearing cap bolt (a): 23 Nm.

Check the springs (2, 4 and 5) for damage and replace them with new ones if necessary.

Rice. 3.78. Installation of steel balls and springs

Install steel balls 3 and springs (2, 4 and 5) for the corresponding shift shaft and tighten the bolts 1 with sealant on the threaded part (Fig. 3.78).

Tightening torque for the retainer bolt (a): 13 Nm.

Rice. 3.79. Installing a new retaining ring: 1 - retaining ring; 2 - drive shaft; 3 - left bearing of the drive shaft

Install a new retaining ring 1 using a special tool (Fig. 3.79).

To fit the outer ring of the left bearing of the intermediate shaft 2, use a special tool and a plastic hammer (Fig. 3.79).

Rice. 3.80. Installing the outer race of the left intermediate shaft bearing

Temporarily place an adjusting washer 3 on the outer ring of bearing 4, install the straight edge on the spacer 1, push on the straight edge and measure "a" (the gap between the surface of the housing 5 and the straight edge) using a feeler gauge 6 (Fig. 3.80).

The gap between the surface of the case and the ruler "a": 0.08–0.12 mm.

Repeating the previous step, select a suitable shim that provides the required clearance and install it on the outer ring of the bearing.

Insert a 0.1 mm feeler gauge to see if the shim is providing the required clearance.

The following shims are available

Rice. 3.81. Installation of the left housing plate: 3 - drive shaft; 5 - intermediate shaft

Install the plate of the left case 2 by inserting its end into the groove of the switch guide 4, then tighten the bolts 1, pre-cover the threaded part of the bolts with a thread sealant (Fig. 3.81).

After tightening the bolts, make sure the countershaft can be rotated by hand while feeling a certain load.

Tightening torque for left housing plate bolt (a): 23 Nm.

Prices for the repair of the Suzuki Liana / Suzuki Liana transmission (mechanical and automatic). Automatic transmission and manual transmission repair. Replacing the clutch.

AUTOKUZOV + provides high-quality repair of the Suzuki Liana box. Each of our clients will be able to make sure that the maintenance and repair of Suzuki Liana transmissions is carried out by competent specialists using 100% high-quality consumables. In the course of work, our employees use only reliable, proven brands and materials. It is also important that the repair of the Suzuki Liana gearbox ((mechanical and automatic)) is carried out without a hint of economy. The advantages of our service are rich experience and high qualifications of each of the masters. We repair automatic transmissions and manual transmissions of Suzuki Liana of any degree of complexity.

Free expert consultation: Discuss the problem, and maybe the cost of repairs will be less. We try to help each of our clients.

To get a discount call:
+7 (495) 774-83-22 and +7 (966) 317-66-17

Repair of the transmission (gearbox) Suzuki Liana can be major or partial. Repair of the box (manual transmission) of the Suzuki Liana must be done only after the initial diagnosis at the car service. Very often, a third-party opinion that the box needs to be repaired turns out to be erroneous. It can also be caused by the clutch, flywheel, and gear selector.

We offer two options for repairing a transmission (manual transmission):

Partial (local) repair of the Suzuki Liana checkpoint - we remove the box, disassemble it, wash and defect. Troubleshooting a box is determining the cause of its failure, indicating a specific malfunction. A list of spare parts for this malfunction is also provided. After agreement, we make repairs to eliminate the specific malfunction that the client has contacted. We do not touch the rest of the components and spare parts in the gearbox.

Overhaul of the Suzuki Liana checkpoint - as well as with partial repairs, the box is removed and completely disassembled, washed and defective. In this case, we are not looking for a specific cause of the breakdown, but we are doing a complete defect diagnosis. All units and spare parts with increased wear, all bearings, oil seals and gaskets are determined and changed.

The Suzuki Liana manual transmission cannot be called the most reliable unit. Quite often, the owners of this car have to deal with wear on the shaft bearing and the need to replace the oil seals. Some other malfunctions may also occur.

Whatever part fails, it is extremely important to contact the service station in a timely manner, that is, when the first symptoms of a malfunction appear. Situations often arise when, for example, a worn out bearing destroys all parts of the manual transmission, after which it remains only to replace it.

When giving a car for repair, it should be borne in mind that not every service station is guaranteed to solve the problem. Inexperienced repair of an amateur can only aggravate the condition of the manual transmission. In order not to waste time and not pay twice, we recommend that you trust the repair of Suzuki Liana manual transmission only to experienced craftsmen.

If you are in Moscow, bring the car to our workshop, which has been engaged in the restoration of manual transmissions for over 20 years. We will diagnose your car for free and provide a good guarantee for the work done.

Call and sign up by phone: +7 (909) 624-64-64 for free diagnostics of the Suzuki Liana manual transmission, as well as the master can advise you on the cost of repairing the manual transmission, as well as on the availability of contract used boxes for your model car in the warehouse.

The indicated prices are for informational purposes only and under no circumstances are a public offer determined by the provisions of Art. 437 of the Civil Code of the Russian Federation. For more detailed information about prices, services, discounts and special offers, please contact the managers by phone: +7 (812) 331-46-31

* The exact cost of the repair is determined by our specialists when diagnosing the manual transmission.

• 7 permanently working qualified technicians with extensive experience in repairing manual transmissions
• 10 lifts for dismantling and installing units, providing the fastest mounting and dismounting in the city
• Safe storage of cars during repairs in our own guarded parking lot, 24-hour video surveillance
• A professional approach to every stage of work, from diagnostics and removal of the gearbox, to testing and running-in after installation

We are ready to purchase a faulty manual transmission from any manufacturer at the maximum price. You can exchange a damaged box for a working one (contract or refurbished). The unit can cost 1,000-20,000 rubles, based on its condition and modification.

Sale of manual transmission parts is carried out taking into account the technical parameters of the manual transmission installed on your car. The selection is carried out by a qualified specialist in strict accordance with the data obtained during the diagnosis of the manual transmission, which revealed the elements to be replaced. To save your money, more than 15,000 manual transmission parts, both new and used, are always in stock.

It will not be difficult for us and, believe me, there will be enough experience to repair any manual transmission of a passenger car or minibus. Our company is present on the service market and has been repairing manual transmissions, manual transmissions for more than 7 years.A simple calculation shows: 7 years is 84 months, and every month at least 50 gearboxes pass through the golden hands of our gearbox repair specialists. As a result, on average, we have 4200 manual transmissions that have received a new life, and 4200 satisfied customers who have found the highest quality and most professional gearbox repair in St. Petersburg.

Assessment of a car owner named Mstislav: 1. Large ground clearance. 2. Wonderful visibility. 3. Huge mirrors. 4. Convenient location of the box and buttons for adjusting the stove with power windows. 5. A serious salon visor, which really fits a lot. 6. When I was building in the country bath, the van fit as much as I could not imagine, in particular, a fireplace (250 kg), a 30m2 carpet, 230 cm long skirting boards, a pile of various packages and bags. Another half of the car was empty.

Category: DIY repair work

Characteristics of the car: The dimensions of the car are as follows, body length - 3034, width - 1100, height - 1863 mm. The wheelbase is 2384 mm. The ground clearance is 186 mm. The car is equipped with a hybrid power unit. The 2-cylinder engine is equipped with a system that provides the output power of the engine. There are 4 valves per cylinder. The diameter of one cylinder is 78 mm, the piston stroke is 70 mm. The engine crankshaft and accelerates to 2000 rpm. The maximum torque is maintained up to 5000 rpm.

Posted by admin: at the request of Evseya

Release date: 23.09.2016

Laughter in the subject: The grandmother, who learned to use the Internet, made a scandal in the electronic queue for a therapist.

Now the intermediate shaft tapered bearing race is correctly inserted. We put the differential in the right half of the manual transmission housing.
1) Install differential assembly into right case.

Further, the manual advises to replace the speedometer sensor, but I would advise you to do this at the very, very, very end of the repair.
2) Insert VSS applied with oil to its O-ring, then tighten it with bolt.

... and install the shafts with their gear selection forks assembled into the right half of the manual transmission housing. Carefully!! Do not damage the gearbox input shaft oil seal !! Before installation, moisten it with oil and also the shaft.
3) Join input shaft, countershaft, low speed gear shift shaft and high speed gear shift shaft assemblies all together, then install them into right case.

NOTE:
Input shaft right bearing on shaft can be installed into right case by tapping shaft with plastic hammer.
Check to make sure that counter shaft is engaged with final gear while installing.

Because: see assembly service manual with drawings.
4) Install 5th & reverse gear shift shaft (1) with 5th & reverse gear shift guide shaft (2) into right case (5). Reverse gear shift arm (4) has to be joined with reverse gear shift lever (3) at the same time.
5) Place reverse gear shift lever, fasten it with bolts after applying thread lock cement.
“A”: Thread lock cement, 99000-32110
I don’t know what kind of cement it is. smeared with Chinese superglue.
Tightening torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

When installing reverse gear shift lever, set distance “a” between lever end and shaft bore to be 5 mm (0.2 in.). Distance “a”: 5 mm (0.2 in.)
Distance “a” can be measured by installing reverse gear shaft provisionally.
When “a” is 5 mm (0.2 in.), Clearance between reverse idler gear groove and shift lever end will be 1 mm (0.04 in.).

Now we insert the intermediate axle of the reverse gear, and unfold the threaded hole in its head opposite the hole in the half of the box body - strictly as prescribed by the Suzuki service manual. If you want to know what hemorrhoids are, do not unfold it correctly, and you will be provided with it.
6) Make reverse idler gear with reverse gear shift lever, insert reverse gear shaft into case through idler gear and then align “A” in shaft with “B” in case.
NOTE:

Make sure that washer has been installed in shaft at above the gear.

And very carefully we smear both of them with high-quality silicone sealant! I use Kazan silicone sealant - moisture curing gasket, not acetic cure sealants.

7) Clean mating surfaces of both right and left cases, coat mating surface of left case with sealant evenly then mate it with right case.
“B”: Sealant, Bond No.1215, 99000-31110

and tighten the bolt securing the head of the reverse gear selection axis. Hopefully you haven't knocked anything off, and her threaded hole, lined up with the yellow straight line, as shown above, was just opposite the hole in the box body. It is recommended, again, to spread with a thread lock and tighten with a force of 23 Newtons per meter or 2.3 kgf-m.
9) Install reverse shaft bolt (4) applied with thread lock cement with aluminum washer and tighten it.
“A”: Thread lock 1322, 99000-32110
Tightening torque
(c): 23 N.m (2.3 kg-m, 17.0 lb-ft)

And by inserting the appropriate springs - ATTENTION, THEY ARE DIFFERENT IN LENGTH! - screw down their plug bolts. We do not lose their washers, if the standard washer is not placed under the plug-bolt, the spring will be compressed so that it will be very difficult to shift the gear. The tightening force is 1.3 kgf-m, I do not advise you to overtighten, if it will be difficult to unscrew it on the machine for inspection of the springs. The table below shows the reference dimensions for the length of the springs from the service manual. If the spring is shorter than the service limit, it can be replaced.

11) Check locating spring for deterioration and replace with new one as necessary.

We measure the clearance of the intermediate shaft bearing, if necessary, we manufacture and install another adjusting distance ring.
After installing the outer cone of the rear tapered bearing of the intermediate shaft and overlaying a spacer ring on it, the top of the spacer ring should protrude from the box housing by 0.08 - 0.12 mm, then when installing the bearing pressing plate, all clearances will be selected to zero with the required preload. The output shaft must not dangle in the box under any circumstances!
Further, in our photo report, in some places, the order of assembly is insignificantly violated in comparison with the Suzuki service manual, partly this is due to the lack of exotic adaptations. Well, in general, it is less time consuming to collect as shown in the pictures.
2) Put a shim on bearing cup provisionally, place straight edge (1) over it and compress it by hand through straight edge, and then measure “a” (Clearance between case surface and straight edge) by using feeler gauge.
Clearance “a”: 0.08 - 0.12 mm (0.0032 - 0.0047 in.) (Shim protrusion)
3) By repeating above step, select a suitable shim which adjusts clearance “a” to specification and put it on bearing cup.
NOTE:

Insert 0.1 mm (0.004 in.) Feeler to know whether or not a shim fulfills specification quickly.

We collect the 5th gear synchronizer node to a heap:
5) Assemble 5th speed synchronizer sleeve (4) and hub (3) with keys (2) and springs (1). NOTE: Short side C in keys, long flange D in hub and chamfered spline F in sleeve should face inward (5th gear side). A = B C: Short side (Inward) D: Long flange (Inward) E: Key way F: Chamfered spline (Inward)
See the photo: we put the driven gear on the end of the intermediate shaft exactly as shown in the photo! How they shot and how according to the service manual!

And we collect and insert the synchronizer itself there, ATTENTION. THE 5TH GEAR - SYNCHRONIZER DRY - NON-SYMMETRIC. SEE the instructions from the SERVICE MANUAL HOW TO SET THEM CORRECTLY. Correctly - with the longer sides: “The long flange of the cracker is installed inward (from the side of the gear)” (literal translation). Also, see the service manual for how to properly install the springs that press these crackers. The only thing that should be noted is that an error in assembling the 5th gear can be corrected on the car by removing the back cover. but extremely time consuming. Check if you did everything right.

11) Fit 5th gear shift fork to sleeve & hub assembly and install them into input shaft, shift shaft and shift guide shaft at once aligning hub oil groove A with shaft mark B.
NOTE:
Long flange of hub faces inward (gear side).

We install in place and fasten the gear engagement mechanism. Before installation, check that your gearbox is in neutral, if not, use a powerful screwdriver in the round hole where it is installed, set all gear forks to neutral, in the same middle position. Everything is very simple there. And everything is clearly visible. By the way, as you can see from the new shiny bolts, we were not without surprises - one of the previous owners of the car tore off the threads in the box body. I had to make the bolts a little longer. Lubricate the lower seat of the eyes of this mechanism with oil. We clean the mating surfaces and smear with the same sealant before installation.

1) Clean mating surface of guide case.
2) Apply grease to select lever shaft bush and select lever washer, and install gear shift and select shaft assembly with new gasket into transmission.
“A”: Grease A, 99000-25010
3) Apply sealant to gear shift guide case No. 2 bolt (5). Tighten gear shift guide case No. 1 bolts (1) and No. 2 bolt (5) to specified torque at the position that clearance “a” is within 1 - 1.5 mm (0.04 - 0.06 in.).
Tightening torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

Screw in 2 bolts on the side of the gear selection mechanism and tighten them with a torque of 2.5 kgf-m. Now you understand why you had to sign them?

4) Install washer and gear shift interlock bolt (2) applied with sealant and them tighten it to specified torque.
“B”: Sealant, Bond No.1215, 99000-31110
Tightening torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
5) Install washer and 5th to reverse interlock guide bolt (3) applied with sealant and then tighten it to specified torque.
“B”: Sealant, Bond No. 1215, 99000-31110
Tightening torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

We clean, degrease, smear with sealant and put the back cover of the box in place. By the way, the bolts there are different: thicker and thinner, those that are thicker - an effort of 2.3 kgf-m, thin - 1 kgf-m. Hooray! The fifth gear is closed.

16) Clean mating surface of both left case and side cover, coat mating surface with sealant evenly, mate it with left case and then tighten bolts.
“B”: Sealant Bond No. 1215, 99000-31110
Tightening Torque:
(a): 10 N.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)