Major Component Assy Disassembly: Disassembly

Remove the transaxle from the vehicle. Refer to Transaxle Assembly Removal and Installation .
Remove the filler plug at the cover.

Fig 1: Identifying Transaxle With Filler Plug
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Remove the bolts from the gearshift lever cover.

Fig 2: Identifying Gearshift Lever Cover Bolts
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Remove the gearshift lever cover.
Remove the gearshift cover gasket.

Fig 3: Identifying Gearshift Lever Cover
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Remove the reverse lever clip.
Remove the reverse assist lever.

Fig 4: Identifying Reverse Lever Clip And Assist Lever
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Bolt the gearshift lever cover to the fixture KM-552.
Position the fixture KM-552 into the base KM-113-2.

Fig 5: Positioning Fixture KM-552 Into Base KM-113-2
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Remove the snap ring, the bushing, the spring, and the intermediate lever.

Fig 6: Identifying Snap Ring, Bushing, Spring And Intermediate Lever
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Remove the shift finger lever pin.

Fig 7: Removing Shift Finger Lever Pin
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Remove the gearshift rod and the shift finger lever.

Fig 8: Identifying Fixture KM-552
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bolt and the speedometer-driven gear from the transaxle housing.

Fig 9: Identifying Bolt And Speedometer-Driven Gear On Transaxle Housing
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Remove the transaxle cover bolts.

Fig 10: Identifying Transaxle Cover Bolts
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Remove the transaxle cover.

Fig 11: Identifying Transaxle Cover
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Shift the transaxle into 2nd gear.
Remove the bearing plate bolts.

Fig 12: Identifying Bearing Plate Bolts
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Remove the bearing plate from the case with the shafts attached.

Fig 13: Removing Bearing Plate From Case With Shafts Attached
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Shift the transaxle into reverse (R).
Bolt the bearing plate to the fixture KM-552 and install the fixture KM-552 into the base KM-113-2.

Fig 14: Identifying Fixture KM-552 And Base KM-113-2
Courtesy of SUZUKI OF AMERICA CORP.
Remove the bolts and the 5th-gear fork from the bearing plate.

Fig 15: Identifying Bolts And 5th-Gear Fork
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Remove the mainshaft-driven 5th-speed assembly snap ring.

Fig 16: Identifying Mainshaft-Driven 5th-Speed Assembly Snap Ring
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Remove the 5th driven gear synchronizer sleeve and the synchronizer gear using the bearing puller J-22888-20-A with the puller legs J-22888-35.

Fig 17: Identifying Bearing Puller J-22888-20-A With Puller Legs J-22888-35
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Remove the mainshaft-driven 5th-gear assembly.

Fig 18: Identifying Bearing Puller J-22888-20-A With Puller Legs J-22888-35
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Remove the brass synchronizer ring.

Fig 19: Identifying Brass Synchronizer Ring
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Remove the needle bearing, the retaining ring, and the thrust washers.

Fig 20: Identifying Needle Bearing, Retaining Ring, And Thrust Washers
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Remove the input drive 5th-gear snap ring.

Fig 21: Identifying Input Drive 5th-Gear Snap Ring
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Remove the input drive 5th gear using the 5th-gear puller KM-553-A.

Fig 22: Identifying 5th-Gear Puller KM-553-A
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Remove the bolts and the 5th-gearshift connector from the bearing plate using the pawl.

Fig 23: Identifying Bolts And 5th-Gearshift Connector On Bearing Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove the four shift-rod plugs using the shift rod remover J-42469 and the slide hammer J-6125-B.

Fig 24: Removing Shift-Rod Plugs Using Shift Rod Remover J-42469 And Slide Hammer J-6125-B
Courtesy of SUZUKI OF AMERICA CORP.
Remove the spring and the rod lock pin from the small plug hole.

Fig 25: Identifying Spring And Rod Lock Pin
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Remove the pin from the reverse gearshift rod/fork assembly.

Fig 26: Locating Pin On Reverse Gearshift Rod/Fork Assembly
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Remove the reverse gearshift rod/fork assembly from the bearing plate.

Fig 27: Identifying Reverse Gearshift Rod/Fork Assembly
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Remove the bolts from the support bracket.

Fig 28: Locating Support Bracket Bolt
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Remove the 1st -- 2nd gearshift fork holding pin.

Fig 29: Locating 1st - 2nd Gearshift Fork Holding Pin
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Drive the 1st -- 2nd gearshift rod out until it is just free of the bearing plate.

Fig 30: Identifying 1st - 2nd Gearshift Rod
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Remove the support bracket from the bearing plate.

Fig 31: Locating Support Bracket
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Remove the 3rd -- 4th gearshift fork holding pin and the 3rd -- 4th gearshift rod.

Fig 32: Identifying 3rd - 4th Gearshift Fork Holding Pin
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Remove the 5th gearshift lever from the bearing plate.

Fig 33: Removing 5th Gearshift Lever From Bearing Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove the 1st -- 2nd gearshift rod.

Fig 34: Identifying 1st - 2nd Gearshift Rod
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Compress the snap ring holding the mainshaft and secure it with the snap ring retainer J-36633.

Fig 35: Identifying Snap Ring Retainer J-36633
Courtesy of SUZUKI OF AMERICA CORP.
Hold the snap ring open at the base of the input shaft using the snap ring pliers.
Remove the mainshaft assembly and the input shaft assembly from the bearing plate.

Fig 36: Identifying Snap Ring Retainer J-36633
Courtesy of SUZUKI OF AMERICA CORP.