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Home >> Suzuki >> 2013 >> Kizashi Base, Automatic CVT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Manual Transaxle) >> 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.
NOTE: Supporting the gear on the concave side of the puller can cause damage to the gear. Be sure to support the gear on the flat side of the puller.
  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: Using an inappropriate hydraulic press or bearing puller could cause personal injury. Make sure that both the hydraulic press and bearing puller are capable of safely bearing a load of at least 5 tons (11, 000 lbs).
    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 in the illustration.
    CAUTION: The shaft (3) will be damaged if the bearing is ground too much. Limit the amount of grinding to the minimum amount necessary.
    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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