Manual Transmission Assembly Dismounting and Remounting: Dismounting

In cabin 

Remove transmission shift control lever referring to TRANSMISSION SHIFT CONTROL LEVER REMOVAL AND INSTALLATION and transfer shift control lever knob.

In engine room 

1. Disconnect negative (-) cable of battery.
2. Remove breather hose (3) from clamp (2) at the rear end of cylinder head.
   Fig 1: Removing Breather Hose

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3. Remove starting motor fixing bolts (2) and then remove starter (1).
   Fig 2: Removing Starting Motor Fixing Bolts

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4. Remove transmission fastening bolts (1).
   Fig 3: Removing Transmission Fastening Bolts

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On lift 

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 4: Removing Flange Bolts

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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 5: Removing Nuts From Joint With Engine

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10. Apply transmission jack (1) and remove engine rear mounting member (2) taking off its bolts.
    Fig 6: Applying Transmission Jack

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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 7: Identifying Transmission Removal Components

Courtesy of SUZUKI OF AMERICA CORP.