Countershaft Assembly - Suzuki Baleno Manual

1. Countershaft
2. L bearing cone
3. 4th gear
4. Puller
(Place flat side up)
1. Countershaft
2. 3rd & 4th gear spacer
3. 3rd gear
4. 2nd gear
5. Puller
(Place fiat side up)
1. Low speed
synchronizer
sleeve
2. Circlip
1. Low speed synchronizer sleeve
& hub assembly
2. 1st gear
3. Puller
(Place flat side up)
1. Metal stick
2. Countershaft R
bearing cone
3. Puller
MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-25

COUNTERSHAFT ASSEMBLY

Disassembly
1) Drive out L bearing cone with 4th gear by using puller and press.
CAUTION:
D Use puller and press that will bear at least 5 ton
(11,000 lb) safely.
D To avoid tooth damage, support 4th gear at flat side
of puller.
2) Apply puller to 2nd gear and drive out 3rd & 4th gear spacer to-
gether with 2nd gear by using press. Needle bearing would
come out with 2nd gear.
CAUTION:
If compression exceeds 5 ton (11,000 lb), release com-
pression once, reset puller support and then continue
press work again.
3) Take out 2nd synchronizer ring.
4) Using special tool, remove circlip.
NOTE:
Correct tool tips to be flat to facilitate removal of circlip.
Special Tool
(A): 09900-06107
5) Apply puller to 1st gear and drive out low speed synchronizer
sleeve & hub assembly with gear by using press.
6) Disassemble synchronizer sleeve & hub assembly.
7) Take out needle bearing from shaft.
8) Remove R bearing cone by using puller, metal stick and press.