Countershaft Disassembly and Reassembly: Disassembly

Remove countershaft rear bearing (1) using bearing puller, metal stick (2) and hydraulic press.

Fig 1: Removing Countershaft Rear Bearing Using Bearing Puller, Metal Stick And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.
Hold hatched area (5) of countershaft assembly (1) with blocks (4) on vise (2) or the like to stop rotation of shaft, and then undo caulking and countershaft front bearing nut (3).
NOTE: The countershaft will be damaged if its splines, gear teeth, or polished portion is griped with a vise.
Do not grip these portions with a vise.

Fig 2: Holding Countershaft Assembly Using Vise And Block
Courtesy of SUZUKI OF AMERICA CORP.
Apply bearing puller to 2nd gear (1), and drive out countershaft front bearing (2), countershaft reverse gear (3), 1st gear (4), countershaft gear needle bearings, countershaft low needle bearing bush, low speed synchronizer assembly (5) and 2nd gear all at once from countershaft using metal stick (6) and hydraulic press.
NOTE: If the gear is supported on the concave side of the bearing puller, the teeth of the gear may be damaged.
Be sure to support the 2nd gear on the flat side of the bearing puller.

Fig 3: Removing Countershaft Assembly Using Metal Stick And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.