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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 176 (Manual Transmission) >> Repair Instructions >> Manual Transmission Assembly Dismounting and Remounting >> Dismounting >> On lift

On lift

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove skid plate (if equipped).
  2. Drain oil from transmission and transfer.
  3. Give match marks (1) on joint flange and propeller shaft as shown in the figure. (front and rear)
  4. Remove flange bolts (2) of rear propeller shaft universal joint and pull out propeller shaft (3).
  5. Remove flange bolts (2) of front propeller shaft universal joint and pull out propeller shaft (3).
    Fig 1: Removing Flange Bolts
    G00798149Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove clutch operating cylinder from transmission. It is not necessary to disconnect clutch hose from operating cylinder.
    NOTE:
    • It is not necessary to drain transmission oil when dismounting transmission and transfer for clutch maintenance only.
    • Work without draining transfer oil is possible if front propeller shaft is dismounted together with transmission and transfer.
  7. Remove clutch housing lower plate.
  8. Disconnect couplers from 4WD switch, back up light switch and speed sensor assembly and release their harness from clamps.
  9. Remove nuts (1) from joint with engine.
    Fig 2: Removing Nuts From Joint With Engine
    G00798150Courtesy of SUZUKI OF AMERICA CORP.
  10. Apply transmission jack (1) and remove engine rear mounting member (2) taking off its bolts.
    Fig 3: Removing Engine Rear Mounting Member Using Transmission Jack
    G00798151Courtesy of SUZUKI OF AMERICA CORP.
  11. After removing mounting member, move rearward transmission and transfer assemblies placed on jack and then lower them.
  12. Remove wiring harness (3) and breather hose (4).
  13. Separate gear shift lever case (5) and transfer assembly (2) (or extension case for 2WD model) from transmission assembly (1).
Fig 4: Separating Gear Shift Lever Case And Transfer Assembly From Transmission Assembly
G00798152Courtesy of SUZUKI OF AMERICA CORP.