Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 354
5B-63 Manual Transmission/Transaxle: For Diesel Engine Model
• Check clearance “d” between synchronizer center
cone (1) and gear (2) while lightly pushing
synchronizer outer ring by the hand, and also check
chamfered tooth of gear and synchronizer center
cone. Also, check gear tooth. Replace with new one if
necessary.
Clearance “d” between synchronizer center cone
and gear (2nd and 3rd)
Standard: 0.2 – 0.9 mm (0.008 – 0.035 in.)
Service limit: 0.1 mm (0.004 in.)
• Check clearance “e” between synchronizer inner ring
(1) and gear (2) while lightly pushing synchronizer
inner ring by the hand, and also check chamfered
tooth of gear and synchronizer inner ring. Also, check
gear tooth. Replace with new one if necessary.
Clearance “e” between synchronizer inner ring
and gear (2nd and 3rd)
Standard: 0.7 – 1.5 mm (0.028 – 0.059 in.)
Service limit: 0.3 mm (0.012 in.)
• Check clearance “a” between fork (1) and sleeve (2).
Replace those parts if it exceeds limit.
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.
Clearance “a” between fork and sleeve
Standard: 0.05 – 0.25 mm (0.002 – 0.010 in.)
Service limit: 0.45 mm (0.018 in.)
• Using “V” blocks (1) and dial gauge (2), check runout.
If runout exceeds limit below, replace main shaft (3).
Main shaft runout
Limit: 0.02 mm (0.0008 in.)
• Check chamfered part of each sleeve for damage and
excessive wear, and replace as necessary.
• Check each synchronizer key and synchronizer key
spring and replace as necessary.
• Check spline portions and replace parts if excessive
wear is found.
• Check bearing for smooth rotation and replace it if
abnormality is found.
2
2
1
“d”
I5JB0B520066-03
1
2
2
1
“e”
I5JB0B520067-03
I5JB0B520068-01
2
3
1
I5JB0B520069-01
Manual Transmission/Transaxle: For Diesel Engine Model 5B-64
Main Shaft Reassembly
S6JB0A5226024
NOTE
• Before installation, wash each part and
apply specified gear oil to sliding faces of
bearing and gear.
• Use new circlips on shaft for installation.
Do not reuse circlips.
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one as
necessary.
2) Apply oil to reverse gear needle bearing (1), and
then install needle bearing, reverse gear (2) and
reverse gear synchronizer ring (3) to main shaft.
3) Assemble 5th & reverse synchronizer sleeve (4),
synchronizer key (5), synchronizer key spring (6)
and hub (7) as shown in figure.
4) Drive in 5th & reverse synchronizer assembly (1)
using bearing puller, special tools and hydraulic
press.
Special tool
(A): 09913–85210
(B): 09945–55410
(C): 09940–54910
5) Select circlip (1) that will make thrust clearance “a” of
synchronizer hub 0.15 mm (0.006 in) or less and
install it.
Available circlip thickness
6) Apply oil to 5th gear needle bearing, and then install
needle bearing, 5th gear (1) and 5th gear
synchronizer ring to main shaft.
7) Drive in main shaft bearing (2) using bearing puller,
special tools and hydraulic press.
Special tool
(A): 09913–85210
(B): 09945–55410
I5JB0B520107-01
1.86 mm (0.073 in.)
2.04 mm (0.080 in.)
1.95 mm (0.077 in.)
(A)
(B)
(C)
1
I5JB0B520071-01
I5JB0B520072-02
(A)
(B)
2
1
I5JB0B520073-01
5B-65 Manual Transmission/Transaxle: For Diesel Engine Model
8) Select circlip (1) that will make thrust clearance “a” of
bearing 0.15 mm (0.006 in) or less and install it.
Available circlip thickness
9) Apply oil to 1st gear needle bearing (1), and then
install needle bearing, 1st gear (2) and 1st gear
synchronizer ring assembly (3) to main shaft.
10) Assemble low speed synchronizer sleeve (4), key
(5), key spring (6) and hub (7) as shown in figure.
11) Drive in low speed synchronizer assembly (1) using
bearing puller, special tools and hydraulic press, in
specified direction as shown in figure.
Special tool
(A): 09913–85210
(B): 09940–54910
12) Select circlip (1) that will make thrust clearance “a” of
synchronizer hub 0.15 mm (0.006 in) or less and
install it.
Available circlip thickness
1.77 mm (0.070 in.)
2.04 mm (0.080 in.)
1.86 mm (0.073 in.)
2.13 mm (0.084 in.)
1.95 mm (0.077 in.)
2.22 mm (0.087 in.)
I5JB0B520074-02
I5JB0B520075-01
[A]: 1st gear side
1.86 mm (0.073 in.)
2.04 mm (0.080 in.)
1.95 mm (0.077 in.)
1
(B)
(A)
1
[A]
I5JB0B520076-02
I5JB0B520077-02
Manual Transmission/Transaxle: For Diesel Engine Model 5B-66
13) Apply oil to 2nd gear needle bearing, and then install
2nd gear synchronizer ring assembly, needle
bearing and 2nd gear (1) to main shaft.
14) Drive in 3rd gear bush (2) using bearing puller,
special tool and hydraulic press.
Special tool
(A): 09913–85210
15) Apply oil to 3rd gear needle bearing (1), and then
install needle bearing, 3rd gear (2) and 3rd gear
synchronizer ring assembly (3) to main shaft.
16) Assemble high speed synchronizer sleeve (4), key
(5), key spring (6) and hub (7) as shown in figure.
17) Drive in high speed synchronizer assembly (1) using
bearing puller, special tools and hydraulic press, in
specified direction as shown in figure.
Special tool
(A): 09913–84510
18) Select circlip (1) that will make thrust clearance “a” of
synchronizer hub 0.105 mm (0.004 in) or less and
install it.
Available circlip thickness
(A)
2
1
I5JB0B520078-02
I5JB0B520108-01
[A]: 3rd gear side
1.500 mm (0.059 in.)
1.635 mm (0.064 in.)
1.545 mm (0.061 in.)
1.680 mm (0.066 in.)
1.590 mm (0.063 in.)
1.725 mm (0.068 in.)
1
(A)
1
[A]
I5JB0B520080-03
I5JB0B520081-01
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст