Manual Transaxle Assembly Disassembly and Reassembly: Disassembly

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

Fig 1: Identifying Left Case Plate Bolts And Left Case Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing set shim.
Remove snap ring (1) using snap ring pliers (4).

Fig 2: Removing Snap Ring Using Snap Ring Pliers
Courtesy of SUZUKI OF AMERICA CORP.
Remove gear shift locating bolts (1), then take out locating springs and steel balls.

Fig 3: Identifying Gear Shift Locating Bolts
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Remove reverse shaft bolt (2) with washer.
Remove transaxle case bolts (1) from outside and another bolts from clutch housing side.
Tapping left case flanges with plastic hammer, remove left case.

Fig 4: Identifying Transaxle Case Bolts And Reverse Shaft Bolt
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 bolts (4) and reverse gear shift lever (5).
Pull out 5th & reverse gear shift guide shaft (6) together with 5th & reverse gear shift shaft (7).
NOTE: When removing 5th & reverse gear shift shaft (7) and guide shaft (6), push up high speed gear shift shaft and shift it to 4th to facilitate removal of 5th & reverse shift shaft.

Fig 5: Identifying Reverse Gear Shaft, Washer And Reverse Idler Gear
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: Removing Input Shaft Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove countershaft left bearing outer race from left case.
Remove differential assembly from right case.