Manual Transmission Unit Disassembly

WARNING: This page is about a different car, the 2004 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.

Remove clutch release bearing (1), release fork (2) and clutch housing (3).

Fig 1: Removing Clutch Release Bearing, Release Fork & Clutch Housing
Courtesy of SUZUKI OF AMERICA CORP.
Remove back-up light switch (1).

Fig 2: Removing Back-Up Light Switch
Courtesy of SUZUKI OF AMERICA CORP.
Remove return spring low bolt (1) and return spring reverse bolt (2).

Fig 3: Removing Return Spring Low Bolt & Return Spring Reverse Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Remove transmission to transfer bolt (1).
Disconnect gear shift inner lever edge (2) from gear shift shaft (4), and remove rear case (3) tapping transmission rear case's end by plastic hammer.

Fig 4: Disconnecting Gear Shift Inner Lever
Courtesy of SUZUKI OF AMERICA CORP.
Drive spring pin (1) out by using special tool and then remove gear shift inner shaft (2) and gear shift inner lever (3) from rear case.
Special tool

(A): 09922-85811

Fig 5: Removing Gear Shift Inner Shaft & Gear Shift Inner Lever From Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft bearing retainer (1).

Fig 6: Removing Input Shaft Bearing Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-rings (1) of input shaft bearing and C-ring (2) of countershaft front bearing.
Special tool

(B): 09900-06107

Fig 7: Removing C-Rings Of Input Shaft Bearing & Of Countershaft Front Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Tapping transmission front case (1) flanges with plastic hammer. Remove transmission front case.

Fig 8: Removing Transmission Front Case
Courtesy of SUZUKI OF AMERICA CORP.
Set transmission intermediate case on vise securely.
NOTE: Use aluminum plates between vise and intermediate case to protect intermediate case against damage.
Remove locating screws (1), locating springs (2) and locating ball (3) as shown in the figure.

Fig 9: Removing Locating Screws, Locating Springs & Locating Ball
Courtesy of SUZUKI OF AMERICA CORP.
Remove low speed gear shift fork bolt (1) and high speed gear shift fork bolt (2).

Fig 10: Removing Low Speed Gear Shift Fork Bolt & High Speed Gear Shift Fork Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlips (1) from high speed gear shift shaft (2) and low gear shift shaft (3) using flat head screw drivers (4) or the like.

Fig 11: Removing Circlips
Courtesy of SUZUKI OF AMERICA CORP.
Remove high speed gear shift shaft (2) and high speed gear shift fork (1).

Fig 12: Removing High Speed Gear Shift Shaft & High Speed Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove interlock pin (1) and straight pin (2) using magnet (3).

Fig 13: Removing Interlock Pin & Straight Pin
Courtesy of SUZUKI OF AMERICA CORP.
Remove low speed gear shift shaft (2) and low speed gear shift fork (1).

Fig 14: Removing Low Speed Gear Shift Shaft & Low Speed Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove interlock pin (1) by using magnet (2).

Fig 15: Removing Interlock Pin
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlips (1) from 5th gear shift shaft (2) and 5th & reverse guide shaft (3) using flat head screw drivers (4) or the like.

Fig 16: Removing Circlips
Courtesy of SUZUKI OF AMERICA CORP.
Drive spring pin (1) out from 5th gear shift fork (2) using special tool.
Special tool

(A): 09922-85811

Fig 17: Driving Spring Pin Out From 5th Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove 5th gear shift shaft (1) and 5th gear shift fork (2).

Fig 18: Removing 5th Gear Shift Shaft & 5th Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove interlock pin (1) from intermediate case (2) using magnet (3).
Remove ball (4) from reverse shift fork (5) using magnet (3).

Fig 19: Removing Ball From Reverse Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Pull out 5th & reverse guide shaft (1) from intermediate case (2).
NOTE: When pulling 5th & reverse guide shaft (1), place hand so as to catch ball (3) jumping out of reverse gear shift fork (4).
Remove compression spring (5) from reverse gear shift fork (4) using magnet.
Remove reverse gear shift fork (4) with reverse gear shift arm (6) from reverse gear shift arm bracket (7).

Fig 20: Removing Reverse Gear Shift Fork With Reverse Gear Shift Arm
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1), and then remove reverse gear shift arm (2) from reverse gear shift fork (3), if necessary.

Fig 21: Removing Reverse Gear Shift Arm From Reverse Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse gear shift arm bracket (1) from intermediate case (2).

Fig 22: Removing Reverse Gear Shift Arm Bracket From Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1) from countershaft (2) using flat head screw drivers (3) or the like.

Fig 23: Removing Circlip From Countershaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove 5th speed synchronizer dog (1) using special tools and adjustable angle wrench (2).
Special tool

(A): 09944-36011

(B): 09913-85230

Fig 24: Removing 5th Speed Synchronizer Dog
Courtesy of SUZUKI OF AMERICA CORP.
Remove 5th & reverse synchronizer ring.
Pull off 5th & reverse synchronizer sleeve (1), countershaft 5th gear assembly (2) and needle bearing (3) together from countershaft (4).

Fig 25: Pulling Off 5th & Reverse Synchronizer Sleeve, Countershaft 5th Gear Assembly & Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove synchronizer key spring (1) and balk levers (2) from countershaft 5th gear (3).
Remove 5th & reverse synchronizer sleeve (4) from countershaft 5th gear (3).

Fig 26: Removing 5th & Reverse Synchronizer Sleeve From Countershaft 5th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1) using special tool, and then remove plate spring (2).
Special tool

(A): 09900-06107

Fig 27: Removing Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Remove thrust washer (2) and pin (1).

Fig 28: Removing Thrust Washer & Pin
Courtesy of SUZUKI OF AMERICA CORP.
Remove main shaft and countershaft bearing plate (1).

Fig 29: Removing Main Shaft & Countershaft Bearing Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse idle gear (1) and shaft (2).

Fig 30: Removing Reverse Idle Gear & Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-ring (1) of countershaft rear bearing using special tool.
Special tool

(B): 09900-06107

Fig 31: Removing C-Ring Of Countershaft Rear Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove countershaft rear bearing (1) from intermediate case using rod (2) and hammer, and then remove countershaft (3).

Fig 32: Removing Countershaft Rear Bearing From Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft assembly (1) with 4th gear synchronizer ring from main shaft assembly (2).
NOTE: When removing input shaft, be careful not to drop roller bearing.

Fig 33: Removing Input Shaft Assembly With 4th Gear Synchronizer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-ring (1) of main shaft bearing using flat head screwdrivers (2) or the like and pull out main shaft assembly (3).
NOTE: If intermediate case (4) is engaged with bearing firmly, tap front face of intermediate case (4) with plastic hammer lightly as it will cause main shaft assembly (3) to come off forward.

Fig 34: Removing C-Ring Of Main Shaft Bearing

Courtesy of SUZUKI OF AMERICA CORP.