Countershaft Disassembly And Assembly: Disassembly

Remove countershaft rear bearing (1) using bearing puller, metal stick (2) and hydraulic press.

Fig 1: Identifying Special Tool On Countershaft Rear Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Hold hatched area (5) of countershaft assembly (1) with "V" blocks (4) on vise (2) or the like to stop rotation of shaft, undo caulking and countershaft front bearing nut (3).
CAUTION: Do not hold spline, gear teeth or abrasive surface of shaft with "V" blocks on vise or the like, otherwise shaft may be damaged.

Fig 2: Identifying Hatched Area Of Countershaft Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Apply bearing puller to 2nd gear (1), and drive out countershaft front bearing (2), countershaft reverse gear (3), 1st gear (4), countershaft gear needle bearings, countershaft low needle bearing bush, low speed synchronizer assembly (5) and 2nd gear all at once from countershaft using metal stick (6) and hydraulic press.
CAUTION: To avoid gear teeth from being damaged, support 2nd gear at flat side of bearing puller.

Fig 3: Identifying Bearing Puller To 2nd Gear & Drive Out Countershaft Front Bearing
Courtesy of SUZUKI OF AMERICA CORP.