Suzuki Grand Vitara JB419. Service manual — part 114

Manual Transmission/Transaxle: 5B-32

Reassembly

1) Apply oil to reverse idle gear needle bearing (1), and

then install reverse idle gear shaft (2), washer (3),
needle bearing and reverse idle gear (4) to reverse
idle gear case (5).

2) Drive in reverse idle gear shaft pin using special tool.

Special tool
(A): 09922–85811

Countershaft and Reverse Idle Gear Inspection

S5JB0B5206026

• Check chamfered teeth of gear for damage and

excessive wear, and replace as necessary.

• Check spline portions and replace parts if excessive

wear is found.

• Check bearing for smooth rotation and replace it if

abnormality is found.

Manual Transmission Adapter Case
Disassembly and Assembly

S5JB0B5206030

Disassembly
Remove oil seal (1) from adapter case using special tool.

Special tool
(A): 09913–50121

Assembly

1) Install new oil seal (1) to adapter case (2) facing its

spring side upward in figure using special tool and
hammer and then apply grease to oil seal lip.

Special tool
(A): 09913–75520

“A”: Grease 99000–25010 (SUZUKI Super Grease A)

Installation position oil seal
“a”: 1.5 – 2.5 mm (0.059 – 0.098 in.)

2

3

3

4

1

5

I5JB0B520110-01

(A)

I5JB0B520095-01

(A)

1

I5JB0A520086-01

I5JB0B520098-01

5B-33 Manual Transmission/Transaxle:

Specifications

Tightening Torque Specifications

S5JB0B5207001

NOTE
The specified tightening torque is also described in the following.
“Manual Transmission Assembly Components”
“Gear Shift Lever Case Assembly Components”
“Gear Shift Shaft and Fork Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0B5208001

NOTE
Required service material is also described in the following.
“Manual Transmission Assembly Components”
“Gear Shift Lever Case Assembly Components”
“Gear Shift Shaft and Fork Components”
“Input Shaft Assembly, Main Shaft Assembly and Countershaft Assembly Components”

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Transmission oil level / filler plug

35

3.5

25.0

)

Transmission oil drain plug

35

3.5

25.0

)

Oil filler plug

35

3.5

25.0

)

Control lever locating bolt

10

1.0

7.5

)

/ )

Case cover bolt

10

1.0

7.5

)

Control lever boot cover bolt

12

1.2

9.0

)

/ )

Back up light switch

39

3.9

28.5

)

Gear shift lever front case bolt

23

2.3

17.0

)

Gear shift lever case plate screw

6

0.6

4.5

)

Engine rear mounting No.1 bolt

55

5.5

40.0

)

Engine rear mounting member bolt

55

5.5

40.0

)

/ )

Engine rear mounting No.2 bolt

55

5.5

40.0

)

/ )

Transmission to engine bolt and nut

55

5.5

40.0

)

Clutch housing plate bolt

11

1.1

8.0

)

Input shaft bearing retainer bolt

26

2.6

19.0

)

Front case bolt

45

4.5

32.5

)

Gear shift locating bolt

19

1.9

14.0

)

Rear bearing plate bolt

22

2.2

16.0

)

Adapter case No.1 bolt

45

4.5

32.5

)

Adapter case No.2 bolt

54

5.4

39.0

)

Reverse idle gear case No.1 bolt and No.2 bolt

26

2.6

19.0

)

Select return bolt

25

2.5

18.0

)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

/ ) / ) / ) / ) / ) / ) /

)

/ ) / ) / )

Sealant

SUZUKI Bond No.1215

P/No.: 99000–31110

)

/ ) / ) / ) / ) / ) / )

Manual Transmission/Transaxle: 5B-34

Special Tool

S5JB0B5208002

09912–34510

09913–50121

Case separator

Oil seal remover

)

)

09913–75510

09913–75520

Bearing installer

Bearing installer

)

)

/ )

09913–76010

09913–84510

Bearing installer

Bearing installer

)

/ ) / )

)

/ )

09913–85210

09922–85811

Bearing installer

Spring pin remover (4.5 mm)

)

/ ) / ) / ) / )

)

/ ) / ) / ) / ) / ) / ) /

)

/ ) / )

09924–07710

09924–74590

Synchronizer hub installer

Input shaft oil seal installer
attachment

)

)

09925–98220

09925–98221

Bearing installer

Bearing installer

)

)

/ )

09940–54910

09945–55410

Front fork oil seal install
driver

Bushing installer

)

/ )

)

/ )

5C-1 Clutch:

Transmission / Transaxle

Clutch

General Description

Clutch (Hydraulic Type) Construction

S5JB0B5301001

The clutch is a diaphragm-spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part, with
a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned on
the transmission input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries
the diaphragm spring in such a way that the peripheral
edge part of the spring pushes on the pressure plate
against the flywheel (with the disc in between), when the
clutch release bearing (incorporated in clutch operating
cylinder) is held back. This is the engaged condition of
the clutch.
Depressing the clutch pedal causes the release bearing
(incorporated in clutch operating cylinder) to advance
and pushes on the tips of the tapered fingers of the
diaphragm spring. When this happens, the diaphragm
spring pulls the pressure plate away from the flywheel,
thereby interrupting the flow of drive from flywheel
through clutch disc to transmission input shaft.
Clutch fluid is supplied from brake fluid reservoir.
Clutch fluid level can be checked by brake fluid level of
brake fluid reservoir.

1. Crankshaft

7. Release bearing

2. Flywheel

8. Input shaft bearing

3. Clutch disc

9. Input shaft

4. Pressure plate

10. Operating cylinder

5. Clutch cover

11. Clutch housing

6. Diaphragm spring

1

2

3

4

5

6

7

10

8

9

11

I5JB0A530001-01