Major Component Assy Disassembly: Disassembly

Remove the transaxle from the vehicle. Refer to TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION .
Remove the filler plug at the cover.

Fig 1: Removing The Filler Plug
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Remove the bolts from the gearshift lever cover.

Fig 2: Removing The Bolts From Gearshift
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Remove the gearshift lever cover.

Fig 3: Removing The Gearshift Lever Cover
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Bolt the gearshift lever cover to the fixture KM-552.
Position the fixture KM-552 into the base KM-113-2.

Fig 4: Positioning The Fixture Into Base
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Remove the snap ring, the bushing, the spring, and the intermediate lever.

Fig 5: Removing The Intermediate Lever
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Remove the shift finger lever pin.

Fig 6: Removing The Shift Finger Lever Pin
Courtesy of SUZUKI OF AMERICA CORP.
Remove the gearshift rod and the shift finger lever.

Fig 7: Removing Gearshift Shift Finger Lever
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Remove the bolt and the speedometer-driven gear from the transaxle housing.

Fig 8: Removing Bolt & Speedometer-Driven Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the transaxle cover bolts.

Fig 9: Removing The Transaxle Cover Bolts
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Remove the transaxle cover.

Fig 10: Removing The Transaxle Cover
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Shift the transaxle into second gear.

Fig 11: Shifting The Transaxle Into Second Gear
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Remove the bearing plate bolts.
Remove the bearing plate from the case with the shafts attached.

Fig 12: Removing The Bearing Plate From The Case
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Shift the transaxle into reverse (R).
Bolt the bearing plate to the fixture KM-552 and install the fixture KM-552 into the base KM-113-2.

Fig 13: Bolting The Bearing Plate To Fixture
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bolts and the fifth-gear fork from the bearing plate.

Fig 14: Removing The Bolts & Fifth-Gear Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft-driven fifth-speed assembly snap ring.

Fig 15: Removing The Fifth-Speed Assembly Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the fifth driven gear synchronizer sleeve and the synchronizer gear using the bearing puller J-22888-20-A with the puller legs J-22888-35.

Fig 16: Removing The Synchronizer Gear
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Remove the mainshaft-driven fifth-gear assembly.

Fig 17: Removing The Mainshaft-Driven Fifth-Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove the brass synchronizer ring.

Fig 18: Removing The Brass Synchronizer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the needle bearing, the retaining ring, and the thrust washers.

Fig 19: Removing The Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the input drive fifth-gear snap ring.

Fig 20: Removing The Fifth-Gear Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the input drive fifth gear using the fifth-gear puller KM-553-A.

Fig 21: Removing The Input Drive Fifth Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bolts and the fifth-gearshift connector from the bearing plate using the pawl.

Fig 22: Removing The Fifth-Gearshift Connector
Courtesy of SUZUKI OF AMERICA CORP.
Remove the four shift-rod plugs using the shift rod remover J-42469 and the slide hammer J-6125-B.

Fig 23: Removing The Shift-Rod Plugs
Courtesy of SUZUKI OF AMERICA CORP.
Remove the spring and the rod lock pin from the small plug hole.

Fig 24: Removing The Spring & Rod Lock Pin
Courtesy of SUZUKI OF AMERICA CORP.
Remove the pin from the reverse gearshift rod/fork assembly.

Fig 25: Removing The Pin From Gearshift Rod/Fork Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove the reverse gearshift rod/fork assembly from the bearing plate.

Fig 26: Removing The Reverse Gearshift Rod/Fork Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bolts from the support bracket.

Fig 27: Removing The Bolts From The Support Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first-second gearshift fork holding pin.

Fig 28: Removing First-Second Gearshift Fork Holding Pin
Courtesy of SUZUKI OF AMERICA CORP.
Drive the first-second gearshift rod out until it is just free of the bearing plate.

Fig 29: Driving The First-Second Gearshift Rod Out
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Remove the support bracket from the bearing plate.

Fig 30: Removing The Support Bracket
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Remove the third-fourth gearshift fork holding pin and the third-fourth gearshift rod.

Fig 31: Removing The Third-Fourth Gearshift Fork Holding Pin
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Remove the fifth gearshift lever from the bearing plate.

Fig 32: Removing The Fifth Gearshift Lever
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first-second gearshift rod.

Fig 33: Removing The First-Second Gearshift Rod
Courtesy of SUZUKI OF AMERICA CORP.
Compress the snap ring holding the mainshaft and secure it with the snap ring retainer J-36633.

Fig 34: Compressing The Snap Ring
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Hold the snap ring open at the base of the input shaft using the snap ring pliers.

Fig 35: Holding The Snap Ring Open
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Remove the mainshaft assembly and the input shaft assembly from the bearing plate.