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Major Component Assy Disassembly: Disassembly

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Identifying Filler Plug
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bolts from the gearshift lever cover.

Fig 2: Removing Bolts From Gearshift Lever Cover
Courtesy of SUZUKI OF AMERICA CORP.
Remove the gearshift lever cover.

Fig 3: Removing Gearshift Lever Cover
Courtesy of SUZUKI OF AMERICA CORP.
Bolt the gearshift lever cover to the fixture KM-552.
Position the fixture KM-552 into the base KM-113-2.

Fig 4: Positioning Fixture KM-552 Into Base KM-113-2
Courtesy of SUZUKI OF AMERICA CORP.
Remove the snap ring, the bushing, the spring, and the intermediate lever.

Fig 5: Removing Snap Ring, Bushing, Spring, And Intermediate Lever
Courtesy of SUZUKI OF AMERICA CORP.
Remove the shift finger lever pin.

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

Fig 7: Removing Gearshift Rod And Shift Finger Lever

G04103725

Courtesy of SUZUKI OF AMERICA CORP.

Remove the bolt and the speedometer-driven gear from the transaxle housing.

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

Fig 9: Removing Transaxle Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the transaxle cover.

Fig 10: Removing Transaxle Cover
Courtesy of SUZUKI OF AMERICA CORP.
Shift the transaxle into second gear.
Remove the bearing plate bolts.

Fig 11: Removing Bearing Plate Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bearing plate from the case with the shafts attached.

Fig 12: Removing Bearing Plate From Case
Courtesy of SUZUKI OF AMERICA CORP.
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: Installing Fixture KM-552 Into Base KM-113-2
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bolts and the fifth-gear fork from the bearing plate.

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

Fig 15: Removing Mainshaft-Driven 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 Fifth Driven Gear Synchronizer Sleeve And Synchronizer Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft-driven fifth-gear assembly.

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

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

Fig 19: Removing Needle Bearing, Retaining Ring, And Thrust Washers
Courtesy of SUZUKI OF AMERICA CORP.
Remove the input drive fifth-gear snap ring.

Fig 20: Removing Input Drive 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 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 Bolts And Fifth-Gearshift Connector From Bearing Plate
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 Four 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 Spring And Rod Lock Pin From Small Plug Hole
Courtesy of SUZUKI OF AMERICA CORP.
Remove the pin from the reverse gearshift rod/fork assembly.

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

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

Fig 27: Removing Bolts From 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: Removing First-Second Gearshift Rod
Courtesy of SUZUKI OF AMERICA CORP.
Remove the support bracket from the bearing plate.

Fig 30: Removing Support Bracket From Bearing Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove the third-fourth gearshift fork holding pin and the third-fourth gearshift rod.

Fig 31: Removing Third-Fourth Gearshift Fork Holding Pin And Third-Fourth Gearshift Rod
Courtesy of SUZUKI OF AMERICA CORP.
Remove the fifth gearshift lever from the bearing plate.

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

Fig 33: Removing 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 Snap Ring Holding Mainshaft
Courtesy of SUZUKI OF AMERICA CORP.
Hold the snap ring open at the base of the input shaft using the snap ring pliers.
Remove the mainshaft assembly and the input shaft assembly from the bearing plate.

Fig 35: Removing Mainshaft Assembly And Input Shaft Assembly From Bearing Plate
Courtesy of SUZUKI OF AMERICA CORP.