Suzuki Grand Vitara JB419. Service manual — part 107
Manual Transmission/Transaxle: 5B-4
4. Gear shift lever case assembly
: Apply sealant 99000-31110 to mating
surface of gear shift lever case assembly
and rear case.
22. Reverse idle gear needle bearing
40. High speed gear shift yoke
5. Adapter case oil seal
: Apply grease 99000-25010 to oil seal lip.
23. Reverse idle gear
41. Low speed gear shift yoke
6. Adapter case No.1 bolt
24. Reverse idle gear case
: Apply sealant 99000-31110 to mating
surface of reverse idle gear case and rear
case.
42. Input shaft bearing retainer oil
seal
: Apply grease 99000-25010 to oil
seal lip.
7. Adapter case No.2 bolt
25. Reverse idle gear shaft
: 54 N
⋅m (5.4 kgf-m, 39.0 lb-ft)
8. Gear shift lever case bolt
26. Back up light switch
: 45 N
⋅m (4.5 kgf-m, 32.5 lb-ft)
9. Select return bolt
: Apply sealant 99000-31110 to all around
thread part of bolt
27. Washer
: 22 N
⋅m (2.2 kgf-m, 16.0 lb-ft)
10. Select return low speed spring (short)
28. Back up light switch pin
: Apply grease 99000-25010 to end of pin.
: 25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
11. Select return 5th & reverse spring (long)
29. Oil level/filler plug
: 26 N
⋅m (2.6 kgf-m, 19.0 lb-ft)
12. Select guide pin
30. Oil drain plug
: 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
13. Oil gutter
31. Transmission front case bolt
: 55 N
⋅m (5.5 kgf-m, 40.0 lb-ft)
14. Rear bearing plate
32. Input shaft bearing retainer
: Apply sealant 99000-31110 to mating
surface of input shaft bearing retainer and
front case.
: 35 N
⋅m (3.5 kgf-m, 25.5 lb-ft)
15. Rear bearing plate bolt
33. Input shaft bearing retainer bolt
: 39 N
⋅m (3.9 kgf-m, 28.5 lb-ft)
16. Pin
34. Transmission to engine bolt
: Do not reuse.
17. Gear shift & select lever assembly
35. Transmission to engine nut
: Apply transmission oil.
18. Reverse shift limit cam
36. Input shaft, main shaft & countershaft
assembly
5B-5 Manual Transmission/Transaxle:
Gear Shift Lever Case Assembly Components
S5JB0B5206002
2
3
[A]
[B]
4
5
1
23
16
15
18
20
10
9
(a)
22
(d)
11
8
(b)
17
13
12
7
(a)
6
12
7
(a)
19
17
21
(c)
14
3
I5JB0B520003-03
[A]: Fix with bolt type
10. Gear shift lever case front plug
21. Gear shift lever case plate
screw
[B]: Fix without bolt type
11. Gear shift shaft
22. Control lever boot cover bolt
1. Gear shift control lever knob
12. Gear shift lever case upper plug
: Apply sealant 99000-31110 to plug.
23. Gear shift lever case rear plug
2. Gear shift control lever boot No.2
13. Gear shift lever case seat
: Apply grease 99000-25010 to inside and outside
of seat.
: 10 N
⋅m (1.0 kgf-m, 7.5 lb-ft)
3. Gear shift control lever assembly
: Apply grease 99000-25010 to bush of
lever.
14. Gear shift lever silencer
: 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Gear shift control boot cover
15. Gear shift lever
: 6 N
⋅m (0.6 kgf-m, 4.5 lb-ft)
5. Gear shift control lever boot No.1
16. Gear shift control lever bush
: Apply grease 99000-25010 to inside of bush.
: 12 N
⋅m (1.2 kgf-m, 9.0 lb-ft)
6. Gear shift lever case
: Apply sealant 99000-31110 to mating
surface of gear shift lever case and rear
case.
17. Pin
: Do not reuse.
7. Control lever locating bolt
: Apply grease 99000-25010 to end of
bolt.
18. Gear shift arm
: Apply transmission oil.
8. Gear shift lever case bolt
19. Gear shift control bush
: Apply grease 99000-25010 to inside and outside
of bush.
9. Gear shift lever case cover bolt
20. Gear shift case plate
Manual Transmission/Transaxle: 5B-6
Gear Shift Shaft and Fork Components
S5JB0B5206004
3
2
6
5
9
1
8
12
11
7
4
10
(a)
14
13
15
13
13
13
13
14
I5JB0B520100-01
1. 5th & reverse gear shift shaft
7. 5th & reverse gear shift yoke
13. Pin
2. High speed gear shift shaft
8. High speed gear shift yoke
14. Gear shift shaft ball
: Apply grease 99000-25010 to ball.
3. Low speed gear shift shaft
9. Low speed gear shift yoke
15. Shift shaft interlock pin
: Apply grease 99000-25010 to pin.
4. 5th & reverse gear shift fork
10. Gear shift locating bolt
: Apply sealant 99000-31110 to bolt thread.
: 19 N
⋅m (1.9 kgf-m, 14.0 lb-ft)
5. High speed gear shift fork
11. Gear shift locating spring
: Do not reuse.
6. Low speed gear shift fork
12. Gear shift locating ball
5B-7 Manual Transmission/Transaxle:
Input Shaft Assembly, Main Shaft Assembly and Countershaft Assembly Components
S5JB0B5206005
2
3
6
7
8
9
10
11
12
14
15
18
19
20
9
8
21
22
24
26
27
8
9
28
29
32
33
34
36
38
39
40
[A]
[B]
[C]
41
42
44
25
43
1
5
17
35
30
37
16
13
4
23
31
I5JB0B520005-01
[A]: Input shaft assembly
15. 2nd gear
32. 5th gear synchronizer ring
[B]: Main shaft assembly
16. 2nd gear needle bearing
33. 5th gear
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