Manual Transmission Unit Disassembly

WARNING: This page is about a different car, the 2006 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.

Reference: MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING

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

Fig 1: Identifying Clutch Release Bearing, Release Fork And Clutch Housing
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Remove back-up light switch (1).

Fig 2: Identifying Back-Up Light Switch
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Remove return spring low bolt (1) and return spring reverse bolt (2).

Fig 3: Identifying Return Spring Low Bolt And Return Spring Reverse Bolt (2)
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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: Identifying Gear Shift Inner Lever Edge, Gear Shift Shaft, Rear Case & Transfer Bolt
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: Identifying Spring Pin, Gear Shift Inner Shaft And Gear Shift Inner Lever
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Remove input shaft bearing retainer (1).

Fig 6: Identifying Input Shaft Bearing Retainer
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Remove C-rings (1) of input shaft bearing and C-ring (2) of countershaft front bearing.
Special Tool

(B): 09900-06107

Fig 7: Identifying C-Rings Of Input Shaft Bearing And C-Ring Of Countershaft Front Bearing
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Tapping transmission front case (1) flanges with plastic hammer.
Remove transmission front case.

Fig 8: Identifying Transmission Front Case
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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: Identifying Locating Screws, Locating Springs And Locating Ball
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Remove low speed gear shift fork bolt (1) and high speed gear shift fork bolt (2).

Fig 10: Identifying Low Speed Gear Shift Fork Bolt And High Speed Gear Shift Fork Bolt
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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: Identifying Circlips, High Speed Gear Shift Shaft, Low Gear Shift Shaft & Flat Head Screw Drivers
Courtesy of SUZUKI OF AMERICA CORP.
Remove high speed gear shift shaft (2) and high speed gear shift fork (1).

Fig 12: Identifying High Speed Gear Shift Shaft And High Speed Gear Shift Fork
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Remove interlock pin (1) and straight pin (2) using magnet (3).

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

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

Fig 15: Identifying Interlock Pin & Magnet
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: Identifying Circlips, 5th Gear Shift Shaft, 5th & Reverse Guide Shaft & Flat Head Screw Drivers
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: Identifying Spring Pin & 5th Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove 5th gear shift shaft (1) and 5th gear shift fork (2).

Fig 18: Identifying 5th Gear Shift Shaft And 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: Identifying Interlock Pin, Intermediate Case, Magnet, Ball & 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: Identifying Intermediate Case, Reverse Gear Shift Fork, 5th & Reverse Guide Shaft, Ball, Compression Spring, Reverse Gear Shift Arm & Reverse Gear Shift Arm Bracket
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: Identifying Circlip, Reverse Gear Shift Arm & Reverse Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse gear shift arm bracket (1) from intermediate case (2).

Fig 22: Identifying Reverse Gear Shift Arm Bracket & 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: Identifying Circlip, Countershaft & Flat Head Screw Drivers
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: Identifying Special Tools, 5th Speed Synchronizer Dog And Adjustable Angle Wrench
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: Identifying 5th & Reverse Synchronizer Sleeve, Countershaft 5th Gear Assembly, Countershaft And 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: Identifying Synchronizer Key Spring, Balk Levers, Countershaft 5th Gear, 5th & Reverse Synchronizer Sleeve & 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: Identifying Circlip, Plate Spring & Special Tool
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Remove thrust washer (2) and pin (1).

Fig 28: Identifying Thrust Washer And Pin
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Remove main shaft and countershaft bearing plate (1).

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

Fig 30: Identifying Reverse Idle Gear And 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: Identifying C-Ring & Special Tool
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: Identifying Countershaft Rear Bearing, Rod & Countershaft
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: Identifying Input Shaft Assembly & Main Shaft Assembly
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: Identifying C-Ring, Flat Head Screwdrivers, Main Shaft Assembly & Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.