Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 342

5B-15 Manual Transmission/Transaxle: For Petrol Engine Model

Gear Shift Lever Front Case Assembly
Disassembly and Reassembly

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Disassembly

1) Remove gear shift case plug.
2) Drive out gear shift arm pin using special tool, and

then disassemble components parts.

CAUTION

Be careful to disconnect gear shift shaft from
gear shift lever front case so that gear shift
locating ball and gear shift locating spring
may be jumped out.

Special tool
(A): 09925–78210

Reassembly

1) Install new gear shift shaft oil seal (1) to gear shift

lever front case using special tool.

Special tool
(A): 09923–46020

2) Assemble components parts referring to “Gear Shift

Lever Front Case Assembly Components: For Petrol
Engine Model”.

3) Set new gear shift arm inner pin (1) and outer pin (2)

facing each gap (“a”, “b”) as shown in figure.
Drive gear shift arm pins by using special tool, till pin
protrusion becomes specified length “c”.

Special tool
(A): 09925–78210

Gear shift arm pin protrusion “c”: 0.5–1.5 mm
(0.020–0.059 in.)

(A)

I5JB0A520012-01

(A)

I5JB0A520013-01

5. Case side

“a”

“b”

(A)

“c”

1, 2

I5JB0A520014-01

Manual Transmission/Transaxle: For Petrol Engine Model 5B-16

Gear Shift Lever Front Case Assembly
Inspection

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• Check that gear shift shaft moves smoothly without

abnormal noise. If abnormality is found, replace
defective part.

• Check bushes and boot for damage and deterioration.

If abnormality is found, replace defective part.

Engine Rear Mounting Replacement

S6JB0A5216017

When replacement of mounting parts are necessary,
torque bolts as specified below.

Tightening torque
Engine rear mounting No.1 bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)
Engine rear mounting member bolt (b): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine rear mounting No.2 bolt (c): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)

Manual Transmission Assembly Dismounting
and Remounting

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Dismounting

1) Disconnect negative (–) cable of battery.
2) Remove transmission shift control lever referring to

“Transmission Shift Control Lever Removal and
Installation: For Petrol Engine Model”.

3) Detach engine harness clamps and ground wire

harness from transmission front case.

4) Remove starting motor fastening bolts (2) and

transmission fastening bolts (1).

5) Disconnect clutch fluid joint from pipe of clutch

operating cylinder assembly referring to “Clutch
Operating Cylinder Assembly Removal and
Installation in Section 5C”.

6) Hoist vehicle.
7) Drain oil from transmission and transfer or extension

case.

8) Remove propeller shafts referring to “Propeller Shaft

Removal and Installation in Section 3D”.

9) Remove exhaust No. 2 pipe.

10) Remove engine under cover.

11) Remove clutch housing lower plates (1).

1. Engine rear mounting member
2. Engine rear mounting

I5JB0A520015-01

I5JB0A520016-01

5B-17 Manual Transmission/Transaxle: For Petrol Engine Model

12) Remove transmission fastening nut (2) and bolts (3).

13) Disconnect the following couplers and release their

harness from clamps.
• Back up light switch
• Transfer shift actuator (if equipped)
• 4L/N switch (if equipped)
• Center differential lock switch (if equipped)

14) Apply transmission jack (1) and remove engine rear

mounting member (2) taking off its bolts.

15) After removing mounting member, move rearward

transmission and transfer or extension case
assemblies placed on jack and then lower them.

16) Separate gear shift control lever rear case assembly

(2) and transfer assembly (3) or extension case from
transmission assembly (1).

Remounting
For remounting, reverse dismounting procedure.
• Apply grease to input shaft.

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

• Slant the rear of the engine down, using support

device (1) and install transmission to engine.

I5JB0A520028-01

I5JB0A520029-01

I5JB0A520030-03

“A”

I5JB0A520031-01

I3JA01520024-01

Manual Transmission/Transaxle: For Petrol Engine Model 5B-18

• Use specified torques as given below.

Tightening torque
Transmission to engine bolt and nut (a): 85 N·m (
8.5 kgf-m, 61.5 lb-ft)
Engine rear mounting member bolt (b): 55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Clutch housing lower plate bolt (c): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Engine rear mounting No.2 bolt (d): 55 N·m (5.5
kgf-m, 40.0 lb-ft)

• Set each clamp for wiring and hose securely.
• Install shift control lever referring to “Transmission

Shift Control Lever Removal and Installation: For
Petrol Engine Model”.

• Connect clutch fluid joint to pipe of clutch operating

cylinder assembly referring to “Clutch Operating
Cylinder Assembly Removal and Installation in
Section 5C”.

• Install exhaust No.2 pipe referring to “Exhaust System

Components: For Petrol Engine Model in Section 1K”.

• Fill gear oil to transmission referring to “Manual

Transmission Oil Change: For Petrol Engine Model”.

• Fill gear oil to transfer or extension case referring to

“Transfer Oil Change: Motor-Shift Type (Transfer with
Shift Actuator) in Section 3C”, “Transfer Oil Change:
Non-Shift Type (Transfer without Shift Actuator) in
Section 3C” or “Extension Case Oil Change: For
Petrol Engine Model”.

• Connect battery and check function of engine, clutch,

transmission and transfer.