Suzuki Vitara (LY) 2016-2017 · Service Manual 5 M/T · Repair Instructions

Manual Transaxle Assembly Components

Precautions: General safety (00)

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1. Transaxle right case 28. Reverse gear shaft
icon2. Transaxle left case
: Apply sealant 99000-31260 to mating surface of left case and right case.
29. Washer
icon3. Gear shift & select shaft assembly
: For details, refer to Gear Shift and Select Shaft Assembly Removal and Installation:5 M/T.
30. Reverse idler gear
4. Transaxle left case plate 31. Reverse gear shaft bolt
icon5. Transaxle side cover
: Apply sealant 99000-31260 to mating surface of side cover and left case.
32. Gasket
6. Back up light switch icon33. Oil seal
: Apply grease 99000-25011 to oil seal lip.
icon7. O-ring
: Apply transaxle oil to O-ring.
34. Outer race
icon8. Differential assembly
: For details, refer to Differential Disassembly and Reassembly:5 M/T.
35. Differential side shim
icon9. Oil level / filler plug
: Apply sealant 99000-31260 to threads.
36. Input oil gutter
icon10. Oil drain plug
: Apply sealant 99000-31260 to threads.
icon37. Input shaft & countershaft assembly
: For details, refer to Input Shaft and Countershaft Components:5 M/T.
11. Oil gutter bolt 38. Gear shift locating bolt
12. Left case plate bolt 39. Breather plug
13. Side cover bolt 40. Breather hose
14. Transaxle case bolt 41. Breather union
15. 5th speed synchronizer ring 42. Breather cover plate
16. 5th speed synchronizer lever 43. Breather cover plate bolt
17. 5th speed synchronizer sleeve & hub icon: 21 N·m (2.1 kgf-m, 15.5 lbf-ft)
icon18. Input shaft nut
: After tightening nut to specified torque, caulk nut securely.
icon: 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
19. Bearing set shim icon: 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
20. Countershaft 5th gear icon: 100 N·m (10.2 kgf-m, 74.0 lbf-ft)
icon21. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.
icon: 19 N·m (1.9 kgf-m, 14.0 lbf-ft)
22. 5th gear shift fork bolt icon: 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
23. 5th gear shift fork icon: 31 N·m (3.2 kgf-m, 23.0 lbf-ft)
24. Needle bearing icon:
 
Apply transaxle oil.
25. Input shaft 5th gear icon: Do not reuse.
26. Reverse gear shift lever    
27. Reverse gear shift lever bolt