Countershaft Disassembly And Reassembly - Suzuki 2006 SX4 Service Manual

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5B-32 Manual Transmission/Transaxle:

Countershaft Disassembly and Reassembly

1) Drive out left bearing cone (2) with 4th gear (3) by

using puller (4) and hydraulic press.

• Use puller and hydraulic press that will

bear at least 5 ton (11,000 lb) safely.

• To avoid tooth damage, support 4th gear

(3) at flat side of puller.

1. Countershaft

2) Apply puller (5) to 2nd gear (4) and drive out 3rd &

4th gear spacer (2) and 3rd gear (3) together with

2nd gear by using hydraulic press. Needle bearing

would come out with 2nd gear.

• If compression exceeds 5 ton (11,000 lb),

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.

1. Countershaft

3) Take out 2nd synchronizer outer ring, center cone

S6RW0C5206021

and inner ring.

4) Using snap ring pliers (3), remove circlip (1).

Correct tool tips to be flat to facilitate

removal of circlip.

2. Low speed synchronizer sleeve

5) Apply puller (3) to 1st gear (2) and drive out low

I2RH01520054-01

speed synchronizer sleeve & hub assembly (1) with

1st gear by using hydraulic press.

To avoid gear tooth from damage, support it

at flat side of bearing puller.

I2RH01520055-01

I7RW01520008-01

I2RH01520057-01

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