Suzuki Grand Vitara JB627. Manual — part 245

5B-3 Manual Transmission/Transaxle:

Repair Instructions

Manual Transmission Assembly Components

S6JB0B5206001

6

9

19

20

21

10

18

5

A

3

8

4

27

OIL

1217G

1217G

2

1

24

1322

23

22

25

26

17

16

15

12

11

28

29

13

14

A

30

31

32

33

7

1217G

OIL

1217G

(a)

(a)

(a)

(a)

(a)

(a)

(a)

34

34

34

35

1217G

37

36

38

1217G

(a)

(a)

(c)

(c)

(c)

(c)

I5JB0A520018-04

1. Transmission front case

: Apply sealant 99000-31260 to mating
surface of front case and rear case.

15. Low gear shift inverse lever

29. 5th speed synchronizer lever

2. Transmission rear case

: Apply sealant 99000-31260 to mating
surface of rear case and adapter case.

16. Reverse gear shift lever

30. 5th speed synchronizer sleeve

3. Adapter case

17. Reverse shift locating

31. 5th speed synchronizer ring

4. Gear shift lever front case assembly

: Apply sealant 99000-31260 to mating
surface of rear case and gear shift lever
front case assembly.

18. O-ring

32. Input shaft needle bearing

5. Adapter case oil seal

: Apply grease 99000-25010 to oil seal lip.

19. Back up light switch

33. Output shaft assembly

6. Adapter case bolt

20. Oil filler plug

: Apply sealant 99000-31260 to all around
thread part of bolt.

34. Transmission to engine bolt

Manual Transmission/Transaxle: 5B-4

Gear Shift Control Lever Rear Case Assembly Components

S6JB0B5206002

7. Knock pin

21. Transmission case bolt

35. Transmission to engine nut

8. Gear shift lever case bolt

: Apply thread lock 99000-32110 to all
around thread part of bolt.

22. Reverse gear shaft

36. Pump seal

9. Oil hole plug

23. Reverse shaft bolt washer

37. Output shaft shim

10. Oil hole gasket

24. Reverse shaft bolt

: Apply thread lock 99000-32110 to all
around thread part of bolt.

38. Drain plug

: Apply sealant 99000-31260 to
all around thread part of bolt.

11. Oil gutter

25. Reverse gear shaft washer

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

12. Knock pin

26. Reverse idler gear

: 85 N

⋅m (8.5 kgf-m, 61.5 lb-ft)

13. Input shaft oil seal

: Apply grease 99000-25010 to oil seal lip.

27. Countershaft shim

: Do not reuse.

14. Low gear shift inverse lever bolt

28. Input shaft & countershaft assembly

: Apply transmission oil.

2

10

11

16

6

13

15

3

4

5

12

7

(a)

14

(d)

(c)

8

(b)

1

17

(b)

9

(c)

7

(a)

I5JB0A520019-08

1. Gear shift control lever knob

9. Gear shift lever rear case bolt

17. Gear shift lever case cover bolt

2. Gear shift control lever boot

10. Gear shift control joint bush

: Apply grease 99000-25010 to bush.

: 9 N

⋅m (0.9 kgf-m, 6.5 lb-ft)

3. Gear shift control lever assembly

: Apply grease 99000-25010 to bush of lever.

11. Gear shift stopper plate

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

4. Gear shift control boot cover

12. Gear shift control shaft

: Apply grease 99000-25010 to sliding part of joint.

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

5. Gear shift control lever No.2 sheet

13. Control shaft joint bolt

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

6. Gear shift lever rear case

14. Control shaft joint nut

: Do not reuse.

7. Control lever locating bolt

: Apply grease 99000-25010 to end of bolt.

15. Gear shift lever case plate

5B-5 Manual Transmission/Transaxle:

Gear Shift Lever Front Case Assembly Components

S6JB0B5206003

8. Gear shift stopper plate nut

16. Gear shift lever rear case plate bolt

17

1322

15

16

3

4

5

18

16

2

14

13

OIL

1

OIL

A

A

12

6

7

11

10

A

9

8

(a)

(a)

I5JB0A520001-02

1. Gear shift shaft

8. Gear shift locating retainer

15. Gear shift lever front case bolt

2. Gear shift lever front case

9. Gear shift locating spring

: Apply grease 99000-25010 to spring.

16. Knock pin

3. Gear shift & select arm

10. Gear shift locating ball

: Apply grease 99000-25010 to ball.

17. Gear shift stop bolt

: Apply thread lock 99000-32110 to bolt thread.

4. Gear shift interlock plate

11. Gear shift shaft boot

18. Gear select return spring

5. Reverse gear shift limit plate

12. Gear shift shaft oil seal

: Apply grease 99000-25010 to seal lip.

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

6. Gear shift arm inner pin

13. Gear shift case bush

: Do not reuse.

7. Gear shift arm outer pin

14. Gear shift case plug

: Apply transmission oil.

Manual Transmission/Transaxle: 5B-6

Gear Shift Shaft and Fork Components

S6JB0B5206004

1322

5

6

7

A

A

6

4

7

A

A

6

7

A

A

6

7

A

A

1

2

3

8

8

8

(a)

1322

5

(a)

1322

5

(a)

1322

5

(a)

I5JB0A520002-02

1. Low speed gear shift shaft

4. Low speed gear shift fork

7. Gear shift shaft ball

: Apply grease 99000-25010 to ball.

2. High speed gear shift fork

5. Gear shift locating bolt

: Apply thread lock 99000-32110 to bolt
thread.

8. Gear shift fork bush

3. 5th & reverse gear shift fork

: Never disassemble.

6. Gear shift locating spring

: Apply grease 99000-25010 to spring.

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)