Suzuki Aerio, Verona 2002-06

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the transaxle oil.
  6.  
  7. Remove or disconnect the following:

    Clutch operating cylinder with hose still attached
     
    Gear control cables
     
    All the wiring harness clamps and connectors involved with the transaxle removal, tag if necessary for location to aid during installation
     
    Ground cable at the transaxle
     
    Starter
     
    Exhaust No. 1 pipe bolts
     

  8.  
  9. Support engine with lifting device.

    Engine under covers
     
    Exhaust No. 1 pipe and exhaust No. 2 pipe
     
    Lower stiffener
     
    Left and right ball joints from steering knuckles
     
    Drive shaft joints
     
    Center shaft support and center shaft
     
    Dynamic damper
     
    Engine rear mounting
     
    Engine rear mounting No. 1 bracket with No. 2 bracket
     
    Transaxle to engine bolts and nut
     

  10.  
  11. Support transaxle with a transmission jack.

    Left engine mounting with bracket
     

  12.  
  13. Remove any remaining attached parts from the transaxle.
  14.  
  15. Pull transaxle out so as to disconnect the input shaft from the clutch disc and then remove it.
  16.  

To install:

  1. Install or connect the following:

    Transaxle assembly. Use care when inserting the input shaft into the clutch assembly. If the spline on the input shaft does not align with the clutch assembly spline, turn the crankshaft slightly to aid in spline alignment.
     
    Left engine mounting with bracket
     
    Transaxle-to-engine bolts and nut. Tighten the nut and bolts to 44 ft. lbs. (61 Nm).
     
    Engine rear mounting No. 1 bracket with No. 2 bracket
     
    Engine rear mounting. Tighten the nuts to 32.5 ft. lbs. (45 Nm).
     
    Dynamic damper. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Center shaft support and center shaft
     
    Drive shaft joints
     
    Left and right ball joints from steering knuckles
     
    Lower stiffener. Tighten the bolts to 7 ft. lbs. (10 Nm).
     
    Exhaust No. 1 pipe and exhaust No. 2 pipe
     
    Engine under covers
     

  2.  
  3. Remove engine lifting device.

    Starter
     
    All the wiring harness clamps and connectors involved with the transaxle removal
     
    Gear control cables
     
    Clutch operating cylinder and hose. Tighten the bolts to 16 ft. lbs. (23 Nm).
     
    Negative battery cable and the ground cable on the transaxle
     

  4.  
  5. Refill the transaxle with the recommended lubricant.
  6.  
  7. Check the function of the engine, clutch and transaxle.
  8.  

 
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