Countershaft Disassembly and Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

Drive out left bearing cone (2) with 4th gear (3) by using puller (4) and hydraulic press.
CAUTION:
- Use puller and hydraulic press that will bear at least 5 ton (11,000 lb) safely.
- To avoid tooth damage, support 4th gear at flat side of puller.
  
  Fig 1: Driving Out Left Bearing Cone With 4th Gear By Using Puller
  Courtesy of SUZUKI OF AMERICA CORP.
Apply puller (5) to 2nd gear (4) and drive out 3rd & 4th gear spacer (2) and 3rd gear (3) together with 2nd gear by using hydraulic press. Needle bearing would come out with 2nd gear.
CAUTION:
- If compression exceeds 5 ton (11,000 lb), release compression once, reset puller support and then continue press work again.
- To avoid gear tooth from being damaged, support it at flat side of bearing puller.
  
  Fig 2: Applying Puller To 2nd Gear
  Courtesy of SUZUKI OF AMERICA CORP.
Take out 2nd synchronizer outer ring, center cone and inner ring.
Using special tool, remove circlip (1).
NOTE: Correct tool tips to be flat to facilitate removal of circlip.

Special Tool
1. 09900-06107
  
  Fig 3: Removing Circlip
  Courtesy of SUZUKI OF AMERICA CORP.
Apply puller (3) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (1) with gear by using hydraulic press.

Fig 4: Driving Out Low Speed Synchronizer Sleeve & Hub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Disassemble synchronizer sleeve & hub assembly.
Take out needle bearing from shaft.
CAUTION: To avoid gear tooth from being damaged, support it at flat side of bearing puller.
Remove right bearing cone (2) by using puller (3), metal stick (1) and hydraulic press.

Fig 5: Removing Right Bearing Cone Using Puller
Courtesy of SUZUKI OF AMERICA CORP.