Suzuki Grand Vitara JB419. Service manual — part 113

Manual Transmission/Transaxle: 5B-28

11) Drive in low speed synchronizer assembly (1) using

bearing puller, special tools and hydraulic press, in
specified direction as shown in figure.

Special tool
(A): 09913–85210
(B): 09940–54910

12) Select circlip (1) that will make thrust clearance “a” of

synchronizer hub 0.15 mm (0.006 in) or less and
install it.

Available circlip thickness

13) Apply oil to 2nd gear needle bearing, and then install

2nd gear synchronizer ring assembly, needle
bearing and 2nd gear (1) to main shaft.

14) Drive in 3rd gear bush (2) using bearing puller,

special tool and hydraulic press.

Special tool
(A): 09913–85210

15) Apply oil to 3rd gear needle bearing (1), and then

install needle bearing, 3rd gear (2) and 3rd gear
synchronizer ring assembly (3) to main shaft.

16) Assemble high speed synchronizer sleeve (4), key

(5), key spring (6) and hub (7) as shown in figure.

[A]: 1st gear side

1.86 mm (0.073 in.)

2.04 mm (0.080 in.)

1.95 mm (0.077 in.)

1

(B)

(A)

1

[A]

I5JB0B520076-02

I5JB0B520077-02

(A)

2

1

I5JB0B520078-02

I5JB0B520108-01

5B-29 Manual Transmission/Transaxle:

17) Drive in high speed synchronizer assembly (1) using

bearing puller, special tools and hydraulic press, in
specified direction as shown in figure.

Special tool
(A): 09913–84510

18) Select circlip (1) that will make thrust clearance “a” of

synchronizer hub 0.105 mm (0.004 in) or less and
install it.

Available circlip thickness

Countershaft Assembly Disassembly and
Reassembly

S5JB0B5206025

Disassembly

1) Remove countershaft rear bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09925–98221

2) Remove circlip (1) from countershaft using snap ring

pliers (2).

[A]: 3rd gear side

1.500 mm (0.059 in.)

1.635 mm (0.064 in.)

1.545 mm (0.061 in.)

1.680 mm (0.066 in.)

1.590 mm (0.063 in.)

1.725 mm (0.068 in.)

1

(A)

1

[A]

I5JB0B520080-03

I5JB0B520081-01

1

(A)

I5JB0B520082-01

1

2

I5JB0B520083-02

Manual Transmission/Transaxle: 5B-30

3) Remove countershaft 5th gear (1) using bearing

puller and hydraulic press.

4) Remove countershaft front bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09925–98221

5) Remove circlip from countershaft using snap ring

pliers and then remove countershaft reduction gear
(1) using bearing puller and hydraulic press.

6) Remove countershaft 3rd gear (1) and spacer (2)

using bearing puller and hydraulic press.

Reassembly

1) Clean all components thoroughly, inspect them for

any abnormality and replace with new one as
necessary.

2) Drive in countershaft 5th gear (1) to countershaft (2)

facing its long flange (3) side downward in figure
using bearing puller, special tools and hydraulic
press.

Special tool
(A): 09913–75510
(B): 09924–07710

3) Install circlip to countershaft using snap ring pliers.
4) Drive in countershaft rear bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09913–76010

5) Drive in countershaft 3rd gear (1) to countershaft (2)

facing its long flange (3) side downward in figure
using bearing puller, special tool and hydraulic
press.

Special tool
(A): 09924–74590

1

I5JB0B520084-01

1

(A)

I5JB0B520085-01

1

I5JB0B520086-01

1

2

I5JB0B520087-01

1

2

(A)

(B)

1

3

I5JB0B520088-03

(A)

1

I5JB0B520089-01

1

(A)

1

3

2

I5JB0B520090-03

5B-31 Manual Transmission/Transaxle:

6) Drive in countershaft high speed gear spacer (1) to

countershaft (2) using bearing puller, special tool and
hydraulic press.

Special tool
(A): 09913–85210

7) Drive in countershaft reduction gear (1) to

countershaft (2) facing its long flange (3) side
downward in figure using bearing puller, special tool
and hydraulic press.

Special tool
(A): 09913–84510

8) Select circlip (1) that will make thrust clearance “a” of

synchronizer hub 0.15 mm (0.006 in) or less and
install it.

Available circlip thickness

9) Drive in countershaft front bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09913–76010

Reverse Idle Gear Assembly Disassembly and
Reassembly

S5JB0B5206033

Disassembly

1) Drive out reverse idle gear shaft pin using special

tool.

Special tool
(A): 09922–85811

2) Remove reverse idle gear shaft (1), reverse idle gear

washer (2), reverse idle gear (3) and reverse idle
gear needle bearing (4) from reverse idle gear case
(5).

1.50 mm (0.059 in.)

1.68 mm (0.066 in.)

1.59 mm (0.063 in.)

(A)

1

2

I5JB0B520091-01

2

1

3

(A)

I5JB0B520092-02

I5JB0B520093-01

(A)

1

I5JB0B520094-02

(A)

I5JB0B520095-01

1

2

2

3

4

5

I5JB0B520109-01