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Home >> Suzuki >> 2011 >> SX4 Base, Automatic CVT >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Manual Transmission) >> Repair Instructions >> Countershaft Disassembly and Reassembly >> Disassembly
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Countershaft Disassembly and Reassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Remove circlip (1) using special tool and then remove washer.
    NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.

    Special Tool 

    1. 09900-06107 
      Fig 1: Removing Circlip Using Special Tool
      G06868659Courtesy of SUZUKI OF AMERICA CORP.
  2. Drive out left bearing (2) and 6th gear (3) using puller (4) and hydraulic press and then remove 5 the gear spacer.
    CAUTION:
    • Use puller and hydraulic press that will bear at least 5 ton (11,023 lb) safely.
    • If compression exceeds 5 ton (11,023 lb), release compression once, reset bearing puller and then continue press work again.
    • To avoid gear tooth from being damaged, support it at flat side of bearing puller.
      Fig 2: Driving Out Left Bearing And 6th Gear Using Puller
      G06868660Courtesy of SUZUKI OF AMERICA CORP.
  3. Apply puller (3) to 4th gear (2) and drive out 5th gear (1) with 4th gear using hydraulic press.
    CAUTION: To avoid gear tooth from damage, support it at flat side of bearing puller.
    Fig 3: Driving Out 5th Gear With 4th Gear Using Hydraulic Press
    G06868661Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove circlip (1) using special tool.
    NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.

    Special Tool 

    1. 09900-06107 
      Fig 4: Removing Circlip Using Special Tool
      G06868662Courtesy of SUZUKI OF AMERICA CORP.
  5. Apply puller (3) to 2nd gear (2) and drive out 3rd gear (1) with 2nd gear using hydraulic press.
    Fig 5: Driving Out 3rd Gear With 2nd Gear Using Hydraulic Press
    G06868663Courtesy of SUZUKI OF AMERICA CORP.
  6. Apply puller (4) to reverse gear (3) and drive out low speed synchronizer sleeve & hub assembly (1), 1st gear (2) with reverse gear using hydraulic press.
    CAUTION: To avoid gear tooth from damage, support it at flat side of bearing puller.
    Fig 6: Driving Out Low Speed Synchronizer Sleeve & Hub Assembly
    G06868664Courtesy of SUZUKI OF AMERICA CORP.
  7. In order to remove right bearing (1) from countershaft, grind with a grinder (2) one part "a" of right bearing as illustrated till it becomes thin.
    CAUTION: Be careful not to grind too far not to damage the shaft (3).
    Fig 7: Removing Right Bearing From Countershaft
    G06868665Courtesy of SUZUKI OF AMERICA CORP.
  8. Break with a chisel (1) the thin ground right bearing (2) and it can be removed.
    Fig 8: Identifying Chisel
    G06868666Courtesy of SUZUKI OF AMERICA CORP.
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