Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 349

5B-43 Manual Transmission/Transaxle: For Diesel Engine Model

Gear Shift Lever Case Assembly Components

S6JB0A5226002

2

4

5

1

22

15

14

17

19

9

21

(d)

10

8

(b)

16

12

11

7

(a)

6

11

7

(a)

18

16

20

(c)

3

13

I6JB0A522001-01

1. Gear shift control lever knob

11. Gear shift lever case upper plug

: Apply sealant 99000-31110 to plug.

21. Control lever boot cover bolt

2. Gear shift control lever boot No.2

12. Gear shift lever case seat

: Apply grease 99000-25010 to inside and outside
of seat.

22. Gear shift lever case rear plug

3. Gear shift control lever assembly

: Apply grease 99000-25010 to bush of
lever.

13. Gear shift lever silencer

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

4. Gear shift control boot cover

14. Gear shift lever

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

5. Gear shift control lever boot No.1

15. Gear shift control lever bush

: Apply grease 99000-25010 to inside of bush.

: 6 N

⋅m (0.6 kgf-m, 4.5 lb-ft)

6. Gear shift lever case

: Apply sealant 99000-31110 to mating
surface of gear shift lever case and rear
case.

16. Pin

: 12 N

⋅m (1.2 kgf-m, 9.0 lb-ft)

7. Control lever locating bolt

: Apply grease 99000-25010 to end of
bolt.

17. Gear shift arm

: Do not reuse.

8. Gear shift lever case bolt

18. Gear shift control bush

: Apply grease 99000-25010 to inside and outside
of bush.

: Apply transmission oil.

9. Gear shift lever case front plug

19. Gear shift case plate

10. Gear shift shaft

20. Gear shift lever case plate screw

Manual Transmission/Transaxle: For Diesel Engine Model 5B-44

Gear Shift Shaft and Fork Components

S6JB0A5226004

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-45 Manual Transmission/Transaxle: For Diesel Engine Model

Input Shaft Assembly, Main Shaft Assembly and Countershaft Assembly Components

S6JB0A5226005

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

Manual Transmission/Transaxle: For Diesel Engine Model 5B-46

Manual Transmission Oil Level Check

S6JB0A5226034

1) Lift up vehicle and check oil leakage.
2) Remove oil level/filler plug (1) with washer and

check oil level is lower end of oil level/filler plug hole
(2). If oil is insufficient, pour specified oil up to plug
hole.

3) Install oil level/filler plug with new washer, and then

tighten it to specified torque.

Tightening torque
Transmission oil level / filler plug (a): 35 N·m (
3.5 kgf-m, 25.0 lb-ft)

Manual Transmission Oil Change

S6JB0A5226006

1) Before changing oil, be sure to stop engine and lift

vehicle horizontally.

2) With vehicle lifted up, check leakage. If leakage

exists, correct or repair it.

3) Remove oil level/filler plug (2) with washer.
4) Remove drain plug (1) with washer, and drain oil.
5) Install drain plug with new washer, and tighten it to

specified torque.

Tightening torque
Transmission oil drain plug (a): 35 N·m (3.5 kgf-
m, 25.0 lb-ft)

NOTE
If water or rust is mixed in drained oil, be
sure to check breather hose and boot of
transmission.

6) Pour new specified oil until oil level reaches bottom

of oil filler plug hole (3) as shown in figure.

NOTE
It is highly recommended to use API 75 W-90
gear oil.

Gear oil specifications
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)

Transmission gear oil capacity
Reference: 2.0 liters (4.2 / 3.5 US / Imp. pt)

[C]: Countershaft assembly

17. Low speed synchronizer hub circlip

34. Input shaft rear bearing

1. Input shaft front bearing circlip

18. 2nd gear synchronizer ring assembly

35. Input shaft rear bearing circlip

2. Input shaft front bearing

19. Low speed synchronizer sleeve

36. Countershaft front bearing

3. Input shaft

20. Low speed synchronizer hub

37. Countershaft front bearing circlip

4. Input shaft needle bearing

21. 1st gear synchronizer ring assembly

38. Countershaft reduction gear

5. High speed synchronizer hub circlip

22. 1st gear

39. Countershaft high speed gear spacer

6. High speed synchronizer sleeve

23. Low gear needle bearing

40. Countershaft 3rd gear

7. 4th gear synchronizer ring

24. Main shaft

41. Countershaft

8. Synchronizer key

25. Reverse gear needle bearing

42. Countershaft 5th gear

9. Synchronizer key spring

26. Reverse gear

43. Countershaft rear bearing circlip

10. High speed synchronizer hub

27. Reverse gear synchronizer ring

44. Countershaft rear bearing

11. 3rd gear synchronizer ring assembly

28. 5th & reverse synchronizer hub

: Do not reuse.

12. 3rd gear

29. 5th & reverse synchronizer sleeve

: Apply transmission oil.

13. 3rd gear needle bearing

30. 5th & reverse synchronizer hub circlip

14. 3rd gear bush

31. 5th gear needle bearing

1, (a)

I5JB0B520101-01

I5JB0B520102-02