Manual Transaxle Assembly Disassembly and Reassembly: Disassembly

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

Remove left case plate bolts (1), and take off left case plate (2).

Fig 1: Removing Left Case Plate Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing set shim.
Remove snap ring (1) using special tool.
Special Tool
1. 09900-06107
  
  Fig 2: Removing Snap Ring Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Remove gear shift locating bolts (1), then take out locating springs and steel balls.
Remove back up lamp switch (2).

Fig 3: Removing Back Up Lamp Switch

Courtesy of SUZUKI OF AMERICA CORP.

Remove reverse shaft bolt (2) with washer.
Remove transaxle case outside bolts (1) and clutch housing bolts.
Tapping left case flanges with plastic hammer, remove left case.

Fig 4: Removing Transaxle Case Outside Bolts And Clutch Housing Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3).
Remove reverse gear shift lever (4).
Pull out 5th & reverse gear shift guide shaft (5) together with 5th & reverse gear shift shaft (6).
NOTE:
- When removing 5th & reverse gear shift shaft (6) and guide shaft (5), push up high speed gear shift shaft and shift it to 4th to facilitate removal of 5th & reverse shift shaft (6).
  
  Fig 5: Removing Reverse Gear Shift Lever
  Courtesy of SUZUKI OF AMERICA CORP.
Tapping input shaft end with plastic hammer, push it out as assembly from case a little, then take out input shaft assembly (1), countershaft assembly (2), high speed gear shift shaft (3) and low speed gear shift shaft (4) all at once.

Fig 6: Tapping Input Shaft End With Plastic Hammer
Courtesy of SUZUKI OF AMERICA CORP.
Remove differential assembly from right case.
Remove countershaft left bearing outer race from left case (1) using special tool.
Special Tool
1. 09913-70123
  
  Fig 7: Removing Countershaft Left Bearing Outer Race From Left Case Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Remove side bearing retainer bolts.
Turn side bearing retainer (1) counterclockwise until it stops, and remove side bearing retainer using 2 flat end rods or the like.

Fig 8: Removing Side Bearing Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove differential side bearing outer race from left case using special tools.
Special Tool
1. 09924-74510
2. 09926-27610
  
  Fig 9: Removing Differential Side Bearing Outer Race From Left Case Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Remove differential assembly from right case.