Suzuki Grand Vitara JB419. Service manual — part 106
Precautions: 5-1
Transmission / Transaxle
Precautions
Precautions
Precautions for Transmission / Transaxle
S5JB0B5000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00 in related manual”.
Fastener Caution
Refer to “Fastener Caution in Section 00 in related manual”.
5B-1 Manual Transmission/Transaxle:
Transmission / Transaxle
Manual Transmission/Transaxle
General Description
Manual Transmission Construction
S5JB0B5201001
The manual transmission consists of the input shaft, main shaft, countershaft and reverse idle gear shaft which are
installed in the die-cast aluminum alloy case. This transmission provides five forward speeds and one reverse speed.
The 1st, 2nd and 3rd speeds are for speed reduction drive, 4th speed is for direct drive 5th speed is for speed
increasing drive. The low speed (1st and 2nd) synchronizer is mounted on the main shaft and engaged with the main
shaft 1st or 2nd gear. The high speed (3rd and 4th) synchronizer is mounted on of the main shaft and engaged with
the main shaft 3rd gear or input shaft 4th gear. The 5th & reverse synchronizer is mounted on the main shaft and
engaged with the main shaft 5th or reverse gear. The gear shift lever case is located at the upper behind the
transmission case and has a cam which prevents direct gear shifting from the 5th speed gear into the reverse gear.
The double cone synchronizing mechanism is provided to 1st gear synchromesh. The triple cone synchronizing
mechanism is provided to 2nd and 3rd gear synchromesh.
As the die-cast aluminum alloy case are sealed with liquid type gasket, it is necessary to use genuine sealant or its
equivalent on its mating surface when reassembling them. Also, the case fastening bolts must be tightened to
specified torque by means of the torque wrench and tightening over or below the specified torque should be avoided.
The description under “Repair Instructions” covers the transfer partially which is next to the transmission as well, but
their gear boxes are independent and each of them has its own drain and filler plugs for the oil change or the level
check.
I5JB0B520001-01
1. Input shaft
6. 3rd gear
11. 5th & reverse synchronizer hub
16. Rear case
2. Transmission front case
7. 2nd gear
12. Main shaft
17. Reverse idle gear
3. Input shaft bearing retainer
8. Low speed synchronizer hub
13. Reverse shift shaft
18. Reverse idle gear shaft
4. 4th gear
9. 1st gear
14. Adapter case
19. Reverse idle gear case
5. High speed synchronizer hub
10. Reverse gear
15. Countershaft
Manual Transmission/Transaxle: 5B-2
Diagnostic Information and Procedures
Manual Transmission Symptom Diagnosis
S5JB0B5204001
Condition
Possible cause
Correction / Reference Item
Gear slipping out of mesh Worn shift fork shaft
Replace.
Worn shift fork or synchronizer sleeve
Replace.
Weak or damaged locating spring
Replace.
Worn bearings on input shaft,
countershaft or main shaft
Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Missing or disengagement of snap
ring(s)
Install or replace.
Gears refusing to
disengage
Weakened or broken synchronizer key
spring
Replace.
Distorted shift shaft or shift fork
Replace.
Hard shifting
Improper clutch pedal free travel
Replace pedal arm and/or clutch master
cylinder.
Distorted or broken clutch disc
Replace.
Damaged clutch pressure plate
Replace clutch cover.
Air in clutch hydraulic system
Bleed air.
Fluid leakage from clutch fluid line
Locate leaking point and repair.
Worn synchronizer ring
Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Distorted shift shaft
Replace.
Noise
Inadequate or insufficient lubricant
Replenish.
Damaged or worn bearing(s)
Replace.
Damaged or worn gear(s)
Replace.
Damaged or worn synchronizer ring
Replace.
Damaged or worn chamfered tooth on
sleeve or gear
Replace.
5B-3 Manual Transmission/Transaxle:
Repair Instructions
Manual Transmission Assembly Components
S5JB0B5206001
25
21
23
21
20
19
18
14
13
17
41
40
39
3
11
10
36
27
30
(h)
1
15
(c)
26
35
(g)
31
(b)
16
16
33
(e)
42
6
(a)
8
(f)
16
31
(b)
7
(b)
7
(b)
38
(d)
37
(d)
34
(g)
29
(h)
24
9
4
9
2
32
12
5
12
28
27
27
22
(j)
I5JB0B520099-02
1. Transmission front case
: Apply sealant 99000-31110 to mating
surface of front case and rear case.
19. Reverse shift limit cam spring
37. Reverse idle gear case No.1 bolt
2. Transmission rear case
: Apply sealant 99000-31110 to mating
surface of rear case and adapter case.
20. Reverse shift shaft
38. Reverse idle gear case No.2 bolt
3. Adapter case
21. Reverse idle gear washer
39. 5th & reverse gear shift yoke
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