Manual Transmission Unit Disassembly

Reference: MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING 

Reference: MANUAL TRANSMISSION ASSEMBLY COMPONENTS 

1. Remove clutch operating cylinder assembly from transmission front case referring to CLUTCH OPERATING CYLINDER ASSEMBLY REMOVAL AND INSTALLATION .
2. Remove adapter case (1) from rear case (2).
3. Remove output shaft assembly (3) from adapter case.
   Fig 1: Identifying Output Shaft Assembly, Adapter And Rear Case

   Courtesy of SUZUKI OF AMERICA CORP.
4. Remove reverse shaft bolt (1) and back up light switch (2).
   Fig 2: Identifying Back Up Light Switch And Reverse Shaft Bolt

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5. Remove gear shift locating bolts (1), then take out locating springs (2) and locating balls (3).
6. Remove rear to front case bolts (4), then separate rear case from front case tapping front case flange with plastic hammer.
   Fig 3: Identifying Transmission Assembly Mounting Bolts

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7. Remove oil gutter.
8. Remove reverse shaft assembly (1).
9. Remove low gear shift inverse lever (4).
10. Remove low speed gear shift shaft (2) and 5th & reverse gear shift fork (3) with 5th speed synchronizer sleeve (5).
    Fig 4: Identifying Reverse Shaft Assembly, Shift Inverse Lever, Gear Shift Shaft, Gear Shift Fork And 5Th Speed Synchronizer Sleeve

    Courtesy of SUZUKI OF AMERICA CORP.
11. Remove input shaft needle bearing, 5th speed synchronizer ring and 5th speed synchronizer levers.
12. Remove input shaft front bearing circlip (1) from case using special tool.

    Special Tool 

    (A): 09900-06106 

    Fig 5: Removing Input Shaft Front Bearing Circlip From Case Using Special Tool

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13. Remove input shaft assembly (1), countershaft assembly (2), high speed gear shift fork (3) and low speed gear shift fork (4) as assembly from front case (5) tapping input shaft end by plastic hammer lightly.
    Fig 6: Identifying Input Shaft, Countershaft Assembly, High And Low Speed Gear Shift Fork, And Front Case

    Courtesy of SUZUKI OF AMERICA CORP.