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Manual Transmission Assembly Dismounting & Remounting: Dismounting

WARNING: This page is about a different car, the 2004 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative (-) cable of battery.
  2. Remove transmission shift control lever referring to TRANSMISSION SHIFT CONTROL LEVER REMOVAL & INSTALLATION  .
  3. For transfer (lever-shift type), remove transfer shift control lever referring to TRANSFER SHIFT CONTROL LEVER REMOVAL & INSTALLATION .
  4. Detach couplers from their bracket and disconnect HO2S lead wires at couplers (1).
    Fig 1: Detaching Couplers From Their Bracket & Disconnecting HO2S Lead Wires At Couplers
    G00762021Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove 3 transmission fastening bolts at engine room with engine harness clamp disconnected from intake connector.
    Fig 2: Locating 3 Transmission Fastening Bolts
    G00762022Courtesy of SUZUKI OF AMERICA CORP.
  6. Hoist vehicle.
  7. Drain oil from transmission referring to MANUAL TRANSMISSION GEAR OIL INSPECTION & CHANGE  .
  8. For 4WD vehicle, drain oil from transfer referring to TRANSFER GEAR OIL INSPECTION & CHANGE (Lever-Shift Type) or TRANSFER GEAR OIL INSPECTION & CHANGE (Motor-Shift Type) .
  9. Remove propeller shaft(s) referring to PROPELLER SHAFT REMOVAL & INSTALLATION .
  10. Remove exhaust No. 1 pipe (1) and No. 2 pipe (2).
    Fig 3: Removing Exhaust Pipes
    G00762023Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove exhaust manifold stiffeners.
  12. Remove starting motor bolts (1).
  13. Remove clutch operating cylinder (2) from transmission. It is not necessary to disconnect clutch hose from operating cylinder.
    Fig 4: Removing Clutch Operating Cylinder
    G00762024Courtesy of SUZUKI OF AMERICA CORP.
  14. Remove clutch housing lower plate.
  15. Remove transmission fastening bolt (1) and nuts (2).
    Fig 5: Removing Transmission Fastening Bolt & Nuts
    G00762025Courtesy of SUZUKI OF AMERICA CORP.
  16. Disconnect couplers from 4WD switch, back up light switch and speed sensor assembly and release their harness from clamps.
  17. Apply transmission jack (1) and remove engine rear mounting member (2) taking off its bolts.
    Fig 6: Removing Engine Rear Mounting Member
    G00762026Courtesy of SUZUKI OF AMERICA CORP.
  18. After removing mounting member, move rearward transmission and transfer assemblies placed on jack and then lower them.
  19. Remove breather hose (1).
  20. Separate gear shift lever case (2) and transfer assembly (3) (or extension case for 2WD model) from transmission assembly (4).
Fig 7: Separating Gear Shift Lever Case & Transfer Assembly Or Extension Case (For 2WD Model) From Transmission Assembly
G00762027Courtesy of SUZUKI OF AMERICA CORP.
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