Countershaft Assembly Disassembly and Assembly - Suzuki Jimny Workshop Manual

1) Remove countershaft rear bearing (1) using bearing puller, metal stick (2) and hydraulic press.

2) Remove countershaft front bearing nut in the same manner as Step 4) of “Disassembly” in Input Shaft Assembly Disassembly and Assembly:K9K Model .

3) Apply bearing puller to 2nd gear (1), and drive out countershaft front bearing (2), countershaft reverse gear (3), 1st gear (4), countershaft gear needle bearings, countershaft low needle bearing, low speed synchronizer assembly (5) and 2nd gear all at once from countershaft using metal stick (6) and hydraulic press.

1) Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.

2) To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.

3) Drive in countershaft rear bearing (1) using special tool and hammer.

4) Apply oil to countershaft gear needle bearing, and then install needle bearing and 2nd gear.

5) Assemble synchronizer sleeve (4) and hub (3) as follows.

6) Drive in low speed synchronizer assembly (1) using special tool and hammer.

7) Install countershaft gear needle bearing, and then countershaft low needle bush, needle bearing and 1st gear (1) to countershaft.

8) Press-fit countershaft reverse gear (2) using special tool and hammer.

9) Press-fit countershaft front bearing (1) using special tool and hammer.

10) Hold countershaft with vise through woodblock, tighten countershaft front bearing nut to specified torque.

11) Caulk countershaft front bearing nut using caulking tool and hammer.