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Home >> Suzuki >> 2004 >> Swift + >> Repair and Diagnosis >> External Pages >> Different car >> Section 38 (Manual Transmission - D16) >> Repair Instructions >> Transmission Disassemble >> Disassembly Procedure
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Disassembly Procedure

WARNING: This page is about a different car, the 2005 Suzuki Swift +, 2005 Pontiac Wave, and 2005 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing Transaxle
    GM1248204Courtesy of GENERAL MOTORS CORP.
  1. Remove the transaxle from the vehicle. Refer to Transmission Replacement .
  2. Remove the filler plug at the cover.
    3. Fig 2: Gearshift Lever Cover & Bolts
    GM1248206Courtesy of GENERAL MOTORS CORP.
  3. Remove the bolts from the gearshift lever cover.
    4. Fig 3: Locating Gearshift Lever Cover
    GM1248207Courtesy of GENERAL MOTORS CORP.
  4. Remove the gearshift lever cover.
    5. Fig 4: Gearshift Lever Cover, KM-552 & J 3289-20
    GM1248209Courtesy of GENERAL MOTORS CORP.
  5. Bolt the gearshift lever cover to the KM-552  (1). See Special Tools .
  6. Position the KM-552  into the J 3289-20  (2). See Special Tools .
    7. Fig 5: Snap Ring, Bushing, Spring & Intermediate Lever
    GM1248211Courtesy of GENERAL MOTORS CORP.
  7. Remove the snap ring, the bushing, the spring, and the intermediate lever.
    8. Fig 6: Shift Finger Lever Pin
    GM1248212Courtesy of GENERAL MOTORS CORP.
  8. Remove the shift finger lever pin (2).
    9. Fig 7: Gearshift Rod & Shift Finger Lever
    GM1248213Courtesy of GENERAL MOTORS CORP.
  9. Remove the gearshift rod (1) and the shift finger lever.
    10. Fig 8: Locating Speedometer-Driven Gear
    GM1248215Courtesy of GENERAL MOTORS CORP.
  10. Remove the bolt and the speedometer-driven gear from the transaxle housing.
    11. Fig 9: Transaxle Cover Bolts
    GM1248217Courtesy of GENERAL MOTORS CORP.
  11. Remove the transaxle cover bolts.
    12. Fig 10: Removing End Cover
    GM1248219Courtesy of GENERAL MOTORS CORP.
  12. Remove the transaxle cover.
    13. Fig 11: Bearing Plate Bolts
    GM1248220Courtesy of GENERAL MOTORS CORP.
  13. Shift the transaxle into 2nd gear.
  14. Remove the bearing plate bolts.
    15. Fig 12: View Of Transmission
    GM1248221Courtesy of GENERAL MOTORS CORP.
  15. Remove the bearing plate from the case with the shafts attached.
    16. Fig 13: Bearing Plate, KM-552 & J 3289-20
    GM1248224Courtesy of GENERAL MOTORS CORP.
  16. Shift the transaxle into reverse (R).
  17. Bolt the bearing plate to the KM-552  (2) and install the KM-552  (2) into the J 3289-20  (1). See Special Tools .
    18. Fig 14: 5th Gear Fork & Bearing Plate
    GM1248225Courtesy of GENERAL MOTORS CORP.
  18. Remove the bolts and the 5th gear fork from the bearing plate.
    19. Fig 15: Mainshaft-Driven 5th Speed Assembly Snap Ring
    GM1248226Courtesy of GENERAL MOTORS CORP.
  19. Remove the mainshaft-driven 5th speed assembly snap ring.
    20. Fig 16: 5th Driven Gear Synchronizer, Sleeve & J22888-20A
    GM1248227Courtesy of GENERAL MOTORS CORP.
  20. Remove the 5th driven gear synchronizer sleeve and the synchronizer gear using the J 22888-20A  (1) with the puller legs J 22888-35. See Special Tools .
    21. Fig 17: Mainshaft-Driven 5th Gear Assembly
    GM1248228Courtesy of GENERAL MOTORS CORP.
  21. Remove the mainshaft-driven 5th gear assembly (4).
    22. Fig 18: Brass Synchronizer Ring
    GM1251665Courtesy of GENERAL MOTORS CORP.
  22. Remove the brass synchronizer ring.
    23. Fig 19: Needle Bearing, Retaining Ring & Thrust Washers
    GM1251666Courtesy of GENERAL MOTORS CORP.
  23. Remove the needle bearing, the retaining ring, and the thrust washers.
    24. Fig 20: Input Drive 5th Gear Snap Ring
    GM1251668Courtesy of GENERAL MOTORS CORP.
  24. Remove the input drive 5th gear snap ring.
    25. Fig 21: Input Drive 5th Gear & KM-553-A
    GM1251669Courtesy of GENERAL MOTORS CORP.
  25. Remove the input drive 5th gear using the KM-553-A  (1). See Special Tools .
    26. Fig 22: 5th Gearshift Connector & Bolts
    GM1251670Courtesy of GENERAL MOTORS CORP.
  26. Remove the bolts and the 5th gearshift connector from the bearing plate using the pawl.
    27. Fig 23: Shift-Rod Plugs, J 42469 & J 6125-B
    GM1251671Courtesy of GENERAL MOTORS CORP.
  27. Remove the 4 shift-rod plugs using the J 42469  (1) and the J 6125-B  (2). See Special Tools .
    28. Fig 24: Spring & Rod Lock Pin
    GM1251672Courtesy of GENERAL MOTORS CORP.
  28. Remove the spring and the rod lock pin from the small plug hole.
    29. Fig 25: Pin & Gearshift Rod/Fork Assembly
    GM1251674Courtesy of GENERAL MOTORS CORP.
  29. Remove the pin from the reverse gearshift rod/fork assembly.
    30. Fig 26: Reverse Gearshift Rod/Fork Assembly & Bearing Plate
    GM1251675Courtesy of GENERAL MOTORS CORP.
  30. Remove the reverse gearshift rod/fork assembly from the bearing plate.
    31. Fig 27: Support Bracket & Bolts
    GM1251678Courtesy of GENERAL MOTORS CORP.
  31. Remove the bolts from the support bracket.
    32. Fig 28: 1st-2nd Gearshift Fork & Holding Pin
    GM1251681Courtesy of GENERAL MOTORS CORP.
  32. Remove the 1st-2nd gearshift fork holding pin.
    33. Fig 29: 1st-2nd Gearshift Rod & Bearing Plate
    GM1251682Courtesy of GENERAL MOTORS CORP.
  33. Drive the 1st-2nd gearshift rod out until it is just free of the bearing plate.
    34. Fig 30: Support Bracket & Bearing Plate
    GM1251683Courtesy of GENERAL MOTORS CORP.
  34. Remove the support bracket from the bearing plate.
    35. Fig 31: 3rd-4th Gearshift Fork, Rod & Holding Pin
    GM1251684Courtesy of GENERAL MOTORS CORP.
  35. Remove the 3rd-4th gearshift fork holding pin and the 3rd-4th gearshift rod.
    36. Fig 32: 5th Gearshift Lever & Bearing Plate
    GM1251685Courtesy of GENERAL MOTORS CORP.
  36. Remove the 5th gearshift lever from the bearing plate.
    37. Fig 33: 1st-2nd Gearshift Rod
    GM1251686Courtesy of GENERAL MOTORS CORP.
  37. Remove the 1st-2nd gearshift rod.
    38. Fig 34: Mainshaft & J 36633
    GM1251687Courtesy of GENERAL MOTORS CORP.
  38. Compress the snap ring holding the mainshaft and secure it with the J 36633  (1). See Special Tools .
    39. Fig 35: Input Shaft & Snap Ring Pliers
    GM1251688Courtesy of GENERAL MOTORS CORP.
  39. Hold the snap ring open at the base of the input shaft using the snap ring pliers (2).
  40. Remove the mainshaft assembly and the input shaft assembly from the bearing plate.
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