Suzuki Grand Vitara JB627. Manual — part 249

5B-19 Manual Transmission/Transaxle:

14) Install output shaft assembly into rear case.
15) Select a countershaft shim and output shaft shim as

follows.
a) Measure depth “a” from mating surface of

adapter case (1) to face processed for
installation of countershaft rear bearing (2) and
measure depth “c” from mating surface of
adapter case to face processed for installation of
output shaft rear bearing (5) using vernier
caliper.

b) Measure height “b” from mating surface of rear

case (3) to countershaft rear bearing (2) and “d”
from mating surface of rear case (3) to output
shaft bearing (6) using vernier caliper.

c) Calculate “a” – “b” and “c” – “d”, and select a

shim according to the following table.

Countershaft shim selection table

Output shaft shim selection table

Clearance “a” – “b”

Thickness of

countershaft shim

1.15 – 1.24 mm

(0.046 – 0.048 in.)

0.90 mm (0.035 in.)

1.25 – 1.34 mm

(0.050 – 0.052 in.)

1.00 mm (0.039 in.)

1.35 – 1.44 mm

(0.054 – 0.056 in.)

1.10 mm (0.043 in.)

1.45 – 1.54 mm

(0.057 – 0.060 in.)

1.20 mm (0.047 in.)

1.55 – 1.64 mm

(0.061 – 0.064 in.)

1.30 mm (0.051 in.)

1.65 – 1.74 mm

(0.065 – 0.068 in.)

1.40 mm (0.055 in.)

1.75 – 1.84 mm

(0.069 – 0.072 in.)

1.50 mm (0.059 in.)

1.85 – 1.94 mm

(0.073 – 0.076 in.)

1.60 mm (0.063 in.)

1.95 – 2.04 mm

(0.077 – 0.080 in.)

1.70 mm (0.067 in.)

2.05 – 2.14 mm

(0.081 – 0.084 in.)

1.80 mm (0.071 in.)

2.15 – 2.24 mm

(0.085 – 0.088 in.)

1.90 (0.90 + 1.00) mm

(0.075 (0.035 + 0.039) in.)

Clearance “c” – “d”

Thickness of

countershaft shim

0 – 0.09 mm (0 – 0.04 in.)

—

0.1 – 0.19 mm

(0.004 – 0.007 in.)

0.1 mm (0.004 in.)

0.2 – 0.29 mm

(0.008 – 0.011 in.)

0.2 mm (0.008 in.)

0.3 – 0.39 mm

(0.012 – 0.015 in.)

0.3 mm (0.012 in.)

0.4 – 0.49 mm

(0.016 – 0.019 in.)

0.4 mm (0.016 in.)

0.5 – 0.59 mm

(0.020 – 0.023 in.)

0.5 mm (0.020 in.)

0.6 – 0.69 mm

(0.024 – 0.027 in.)

0.6 mm (0.024 in.)

0.7 – 0.79 mm

(0.028 – 0.031 in.)

0.7 mm (0.028 in.)

“a”

“b”

“d”

2

“c”

5

1

3

4

6

I5JB0A520049-02

Manual Transmission/Transaxle: 5B-20

16) Install selected countershaft shim and output shaft

shim to adapter case.

17) Clean mating surface of both rear case (1) and

adapter case, and uniformly apply sealant to rear
case as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter, and then
mate it with adapter case.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

18) Install rear case to adapter case. Tighten case bolts

(2) to specified torque.

Tightening torque
Adapter case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)

19) Install transfer assembly to transmission assembly.

Tighten transfer fastening bolts to specified torque
referring to “Transfer Assembly Components in
Section 3C”.

20) Install gear shift control lever rear case assembly

and gear shift lever front case assembly referring to
“Gear Shift Control Lever Rear Case Assembly
Removal and Installation” and “Gear Shift Lever
Front Case Assembly Removal and Installation”.

21) Install clutch operating cylinder assembly to

transmission front case referring to “Clutch
Operating Cylinder Assembly Removal and
Installation in Section 5C”.

Locating Spring Inspection

S6JB0B5206021

Check locating springs for deterioration and replace with
new ones if necessary.

Locating spring free length
Standard: 44.6 mm (1.756 in.)
Service limit: 40.1 mm (1.579 in.)

Input Shaft Disassembly

S6JB0B5206022

1) Remove snap ring.
2) Remove input shaft front bearing (1) using bearing

puller and hydraulic press.

3) Remove input shaft union.
4) Hold hatched area (5) of input shaft assembly (1)

with “V” blocks (4) on vise (2) or the like to stop
rotation of shaft, undo caulking and input shaft 5th
hub nut (3).

CAUTION

!

Do not hold spline, gear teeth or abrasived
surface of shaft with vise through “V” blocks
or the like, otherwise shaft components may
be damaged.

2, (a)

2, (a)

2, (a)

2, (a)

“A”

1

I5JB0A520050-01

I5JB0A520051-01

1

2

3

5

4

I5JB0A520052-01

5B-21 Manual Transmission/Transaxle:

5) Apply bearing puller to 4th gear (1), and drive out 5th

speed synchronizer hub (2), 3rd gear (3), high speed
gear needle bearings, 3rd gear bush, high speed
synchronizer assembly (4) and 4th gear all at once
from input shaft using metal stick (5) and press.

CAUTION

!

To avoid gear teeth from being damaged,
support 4th gear at flat side of bearing puller.

Input Shaft Inspection

S6JB0B5206023

• Check clearance “a” between synchronizer ring (2)

and gear (1), key slot width “b” in synchronizer ring
and each chamfered tooth of gear and synchronizer
ring and replace with new one, if necessary. Also,
check gear tooth.

Clearance “a” between synchronizer ring and
gear (Input shaft) (3rd and 4th)
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)

Key slot width “b” (3rd and 4th synchronizer ring)
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)

• Measure width of high speed gear shift fork end “a”

and groove width of high speed synchronizer sleeve
“b”, 5th & reverse gear shift fork end “a” and groove
width of 5th speed synchronizer sleeve “b” and then
calculate clearance “c” as follows:

If clearance exceeds limit, replace fork bush (1) and
sleeve.

Clearance “c” between fork and sleeve for high
speed and 5th speed
Standard: 0.3 – 0.5 mm (0.012 – 0.020 in.)
Limit: 1.0 mm (0.039 in.)

• Check diameter of input shaft (1) and needle bush (2)

as shown in the figure. If measured value is out of
specification, replace input shaft and/or bush.

Input shaft and needle bush specifications
(diameter)

2

3

1

5

4

I5JB0A520053-01

I5JB0A520054-01

Clearance “c”

=

“b”

–

“a”

Measuring

portion

Standard

“a”

30.002 – 30.015 mm

(1.1812 – 1.1816 in.)

“b”

34.950 – 34.991 mm

(1.3760 – 1.3775 in.)

“c”

30.959 – 30.975 mm

(1.2189 – 1.2194 in.)

“d”

27.987 – 28.000 mm

(1.1018 – 1.1023 in.)

“e”

27.967 – 27.980 mm
(1.1011 – 1.1015 in.)

“f”

19.975 – 19.991 mm

(0.7865 – 0.7870 in.)

“g”

28.000 – 28.013 mm

(1.1024 – 1.1028 in.)

“h”

34.975 – 34.991 mm

(1.3770 – 1.3775 in.)

1

“a”

“b”

I5JB0A520055-01

“c”

“d”

“e”

“f”

“g” “h”

“b”

“a”

1

2

I5JB0A520056-01

Manual Transmission/Transaxle: 5B-22

• Using “V” blocks (1) and dial gauge (2), check runout.

If runout exceeds limit below, replace input shaft (3).

Input shaft runout
Limit: 0.02 mm (0.0008 in.)

• Using cylinder gauge (1), check inside diameter of

each gear. If its inside diameter exceeds specification,
replace it.

Inside diameter (standard) of gear
3rd and 4th gear: 40.000 – 40.025 mm (1.5748 –
1.5757 in.)

• Check chamfered part of each sleeve for damage and

excessive wear, and replace as necessary.

• Check each synchronizer key and synchronizer spring

and replace as necessary.

• Check spline portions and replace parts if excessive

wear is found.

Input Shaft Reassembly

S6JB0B5206024

NOTE

• Before installation, wash each part and

apply specified gear oil to sliding faces of
bearing and gear.

• Use new snap rings on shaft for

installation. Don’t reuse snap rings.

1) Clean all components thoroughly, inspect them for

any abnormality and replace with new ones as
necessary.

2) To ensure lubrication, air blow oil holes (1) and make

sure that they are free from any obstruction.

3) Drive in input shaft front bearing (1) to input shaft

using special tool and hammer and then install snap
ring in specified direction as shown in figure.

Special tool
(A): 09940–51710

NOTE
Input shaft front bearing circlip (2) must be
installed before input shaft front bearing is
installed.

4) Apply oil to high speed gear needle bearing (5), and

then install needle bearing, 4th gear (5) and high
speed synchronizer ring (7) to input shaft.

2

3

1

I5JB0A520057-01

IYSQ01522099-01

A: Bearing side

1

1

I5JB0A520058-01

(A)

1

2

A

2

I5JB0A520059-01