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Old 03-09-2009, 02:53 AM   #8
DOCTORBILL
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Re: 94 Metro 5 Speed Manual Transmission Rebuild - PART 2 - Assembly

. . . . . . . . . . . . . Installing the Shift Rod . . . . . . . . . . . . . . .

I wiped off and oiled the Gear Shift Shaft Rod and inserted it into the Shift Boot and up
into the shaft Shaft Oil Seal and all the way in.



The "Ball" that allows the Gear Shift Rod to click into three positions was installed, followed by the
Spring and Bolt with Washer and tightened.

This Bolt is supposed to have a sealant applied to keep it from coming loose.
.......(Suzuki Bond No. 1215)
Same as "Permatex Blue Medium Strength Threadlocker", methinks.....

Permatex Med Strength Threadlocker Blue Gel

ALSO - for later on...the case is supposed to be sealed with Suzuki Bond 1215.
I called Suzuki Parts - don't have 1215, but they do have 1207B (squeeze tube) for $25. (!)
I decided that I will use Permatex 599 RTV Silicone Sealant (Ultra Grey).

Permatex® Ultra Grey® Rigid High-Torque RTV Silicone Gasket Maker


Anything white in these pictures tends to screw up the Camera's exposure system...

The Shift Shaft Rod was turned as it was when I disassembled the Transmission, and Thread
Seal was used to attach the Shift "Arm" with the bolt on the outside.



The Countershaft R-Bearing Race Cup was pressed into it's appropriate place
next to where the Differential goes in.
Do this first since you cannot get the cup into the hole with the Differential in place!



I then lowered the Differential Assembly back into the Case and when it is in, the large Gear
is about 2 mm below the edge of the Case.



According to the Manual, page 7A - 32, I now install the "Speedometer Driven Gear Case Assembly" into the Case.



Next comes "the fun part"....

DoctorBill
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Last edited by DOCTORBILL; 03-10-2009 at 08:59 PM.
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