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Home >> Suzuki >> 2013 >> Kizashi Base, Automatic CVT Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 87 (Manual Transmission/Transaxle) >> Repair Instructions >> Countershaft Disassembly and Reassembly >> Disassembly
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Countershaft Disassembly and Reassembly: Disassembly

WARNING: This page is about a different car, the 2010 Suzuki Kizashi. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove circlip (1) using special tool and then remove washer.

    Special Tool 

    1. 09900-06107 
    Fig 1: Removing Circlip Using Special Tool
    G06528828Courtesy of SUZUKI OF AMERICA CORP.
  2. Remove 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 bears at least 5000 kgf (11023 lbf) safely.
    • If compression exceeds 5000 kgf (11023 lbf), 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: Removing Left Bearing And 6th Gear Using Puller
      G06528829Courtesy of SUZUKI OF AMERICA CORP.
  3. Apply puller (3) to 4th gear (2) and remove 5th gear (1) with 4th gear using hydraulic press.
    CAUTION: To prevent gear tooth from being damaged, support it at flat side of bearing puller.
    Fig 3: Identifying 4th Gear, 5th Gear And Puller
    G06528830Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove circlip (1) using special tool.

    Special Tool 

    1. 09900-06107 
    Fig 4: Removing Circlip Using Special Tool
    G06528831Courtesy of SUZUKI OF AMERICA CORP.
  5. Apply puller (3) to 2nd gear (2) and remove 3rd gear (1) with 2nd gear using hydraulic press.
    Fig 5: Identifying 2nd Gear, 3rd Gear And Puller
    G06528832Courtesy of SUZUKI OF AMERICA CORP.
  6. Apply puller (4) to reverse gear (3) and remove low speed synchronizer sleeve & hub assembly (1), 1st gear (2) with reverse gear using hydraulic press.
    CAUTION: To prevent gear tooth from being damaged, support it at flat side of bearing puller.
    Fig 6: Identifying Low Speed Synchronizer Sleeve & Hub Assembly And 1st Gear
    G06528833Courtesy of SUZUKI OF AMERICA CORP.
  7. Grind portion "a" of right bearing (1) using grinder (2) as shown.
    CAUTION: Be careful not to damage countershaft (3) while grinding bearing.
    Fig 7: Identifying Right Bearing Grind Portion
    G06528834Courtesy of SUZUKI OF AMERICA CORP.
  8. Break the thinnest portion of bearing inner race (2) with a chisel (1) and remove bearing.
    Fig 8: Removing Bearing Inner Race With Chisel
    G06528835Courtesy of SUZUKI OF AMERICA CORP.
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