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Home >> Suzuki >> 2013 >> SX4 Crossover, Standard Trans >> Repair and Diagnosis >> Transmission >> Manual Transmission/Transaxle >> Repair Instructions >> Countershaft Disassembly and Reassembly >> Disassembly
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Countershaft Disassembly and Reassembly: Disassembly

CAUTION: 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.
    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. Remove countershaft 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: 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: 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: 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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