Category: Suzuki Tech

       Next we go to the front of the transmission and remove the clutch release bearing. Now you can see the 8 bolts that hold the input shaft bearing retainer in place. You will also note that even when the bolts have been removed, it is very difficult to remove the retainer. There […]

           Back at the lower case, you can easily remove the reverse gear shaft and idler gear. Set it aside. Next we turn our attention to the countershaft. Using a bearing puller, remove the countershaft rear bearing. This is the first of three bearings you will replace on the countershaft. Being […]

      The factory service manual says to press out the countershaft using a hydraulic press. I accomplished the same thing using a brass drift and a small sledge hammer. Do not use the hammer by itself, you WILL damage the countershaft and you run the risk of cracking the case if you miss… You […]

           When you first look at the main shaft, it may appear very daunting. But as long as you have a large workbench where you can lay everything out in order (and you have your Factory Service Manual handy) it’s not really tough. This is actually two shafts. The main shaft […]

       Your rebuild kit should include all of the main bearings as well as the needle bearings, so remember to swap in the new components as you go. As you (carefully) pull the main shaft assembly apart, you will notice three (3) ball bearings in the mix. Don’t lose these. Also, don’t try […]

      The needle bearings should slide easily with no obstructions. And don’t forget the circlips as you go. Remember the input shaft we set aside earlier? You will need to replace the bearing on the end of the input shaft. Use a bearing puller for removal and then press the new bearing into […]

      Bolt the extension case back into place and don’t forget the reverse shift rim bolt that we pointed out earlier. Then we concentrate on the shift tower. The shifter locating bolt is a commonly replaced item, as it is very prone to wear. There are two different sizes based on the model […]

          Here we finally close up the case by replacing the input shaft housing.  Finally a new clutch release bearing (aka – the throwout bearing) tops off the input shaft. Remember to replace the pilot bearing in your flywheel also, or you may experience a situation where the vehicle still wants […]

Next we remove the ring gear bolts and carefully remove the ring gear, setting it aside.  Now we turn our attention to the ARB Air Locker. You will notice when you press the bearings back on that one of the bearing journals is longer than the other. This is the way they get the air […]