Main Shaft Disassembly

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Remove circlip (1) from main shaft (2) as shown in the figure.

Fig 1: Removing Circlip From Main Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Pull out 5th gear (1), needle bush (2), needle bearing (3), main shaft bearing (4) and low gear (5) with bearing puller (6) and hydraulic press (7).

Fig 2: Pulling Out 5th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove synchronizer ring and ball (1).

Fig 3: Removing Synchronizer Ring And Ball
Courtesy of SUZUKI OF AMERICA CORP.
Pull out low speed sleeve / hub assembly (1), needle bearing and 2nd gear (2) from main shaft.

Fig 4: Pulling Out Low Speed Sleeve/Hub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Pull off synchronizer springs/keys and low speed sleeve from hub.
Remove circlip from front part of main shaft and pull out 3rd gear (1), needle bearing, synchronizer ring and high speed sleeve/hub assembly (2).

Fig 5: Pulling Out 3rd Gear
Courtesy of SUZUKI OF AMERICA CORP.