Mainshaft Disassembly and Assembly: 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 mainshaft bearing using the universal bearing puller J-22912-01.

Fig 1: Removing Mainshaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the snap ring.

Fig 2: Removing Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first gear, the flat-type first-gear needle bearing, and the mainshaft wear plate.

Fig 3: Removing First Gear, Flat-Type First-Gear Needle Bearing, And Mainshaft Wear Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove the synchronizer hub sleeve that contains the synchronizer spring.
Remove the outer blocking ring.

Fig 4: Removing Outer Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the keys from the first-second synchronizer gear.

Fig 5: Removing Keys From First-Second Synchronizer Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the barrel-type first-gear needle bearing.

Fig 6: Removing Barrel-Type First-Gear Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the snap ring and the washer.

Fig 7: Removing Snap Ring And Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first-second synchronizer gear from the mainshaft.

Fig 8: Removing First-Second Synchronizer Gear From Mainshaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first-second gear blocking ring.

Fig 9: Removing First-Second Gear Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the second gear using the universal bearing puller J-22912-01.

Fig 10: Removing Second Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the second-gear needle bearing.

Fig 11: Removing Second-Gear Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the ring and the thrust washer.

Fig 12: Removing Ring And Thrust Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the third gear and the synchronizer blocking ring.

Fig 13: Removing Third Gear And Synchronizer Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Separate the synchronizer blocking ring from the third gear.

Fig 14: Separating Synchronizer Blocking Ring From Third Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the third-gear needle bearing from the mainshaft.

Fig 15: Removing Third-Gear Needle Bearing From Mainshaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove the synchronizer sleeve containing the keys and the spring.

Fig 16: Removing Synchronizer Sleeve Containing Keys And Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the snap ring and the washer from the mainshaft.

Fig 17: Removing Snap Ring And Washer From Mainshaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove the third-fourth synchronizer gear containing the synchronizer spring.

Fig 18: Removing Third-Fourth Synchronizer Gear Containing Synchronizer Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the fourth-gear assembly.

Fig 19: Removing Fourth-Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Separate the synchronizer blocking ring from the fourth gear.

Fig 20: Separating Synchronizer Blocking Ring From Fourth Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the fourth-gear needle bearing, the ring, and the thrust washer.

Fig 21: Removing Fourth-Gear Needle Bearing, Ring, And Thrust Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft bearing.

Fig 22: Removing Mainshaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.