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Home >> Suzuki >> 2000 >> Vitara JS, 2D Utility, 1.6, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - Type "1" 5-Speed >> Transmission Disassembly
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Transmission Disassembly

  1. Remove 12 bolts and separate rear case. Remove clutch release bearing from input shaft. Remove 8 clutch housing bolts and clutch housing from upper and lower case.
  2. Remove 8 input shaft bearing bolts. On 2WD extension case, remove oil seal, select return spring bolts, return springs and guide pins. See Fig 1 . On all models, remove input shaft bearing retainer using 2 screwdrivers. See Fig 2 .
  3. Remove 10 upper case-to-lower case bolts. Using Case Separator (Suzuki 09912-34510), separate case halves. See Fig 3 . Remove mainshaft and input shaft assembly.
Fig 1: Exploded View Of Extension Case Components (2WD)
G99I03795Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing Input Shaft Bearing Retainer
G99A03796Courtesy of GENERAL MOTORS CORP.
Fig 3: Separating Upper & Lower Case
G93J24272Courtesy of GENERAL MOTORS CORP.