Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 355

5B-67 Manual Transmission/Transaxle: For Diesel Engine Model

Countershaft Assembly Disassembly and
Reassembly

S6JB0A5226025

Disassembly

1) Remove countershaft rear bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09925–98221

2) Remove circlip (1) from countershaft using snap ring

pliers (2).

3) Remove countershaft 5th gear (1) using bearing

puller and hydraulic press.

4) Remove countershaft front bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09925–98221

5) Remove circlip from countershaft using snap ring

pliers and then remove countershaft reduction gear
(1) using bearing puller and hydraulic press.

6) Remove countershaft 3rd gear (1) and spacer (2)

using bearing puller and hydraulic press.

1

(A)

I5JB0B520082-01

1

2

I5JB0B520083-02

1

I5JB0B520084-01

1

(A)

I5JB0B520085-01

1

I5JB0B520086-01

1

2

I5JB0B520087-01

Manual Transmission/Transaxle: For Diesel Engine Model 5B-68

Reassembly

1) Clean all components thoroughly, inspect them for

any abnormality and replace with new one as
necessary.

2) Drive in countershaft 5th gear (1) to countershaft (2)

facing its long flange (3) side downward in figure
using bearing puller, special tools and hydraulic
press.

Special tool
(A): 09913–75510
(B): 09924–07710

3) Install circlip to countershaft using snap ring pliers.
4) Drive in countershaft rear bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09913–76010

5) Drive in countershaft 3rd gear (1) to countershaft (2)

facing its long flange (3) side downward in figure
using bearing puller, special tool and hydraulic
press.

Special tool
(A): 09924–74590

6) Drive in countershaft high speed gear spacer (1) to

countershaft (2) using bearing puller, special tool and
hydraulic press.

Special tool
(A): 09913–85210

1

2

(A)

(B)

1

3

I5JB0B520088-03

(A)

1

I5JB0B520089-01

1

(A)

1

3

2

I5JB0B520090-03

(A)

1

2

I5JB0B520091-01

5B-69 Manual Transmission/Transaxle: For Diesel Engine Model

7) Drive in countershaft reduction gear (1) to

countershaft (2) facing its long flange (3) side
downward in figure using bearing puller, special tool
and hydraulic press.

Special tool
(A): 09913–84510

8) Select circlip (1) that will make thrust clearance “a” of

synchronizer hub 0.15 mm (0.006 in) or less and
install it.

Available circlip thickness

9) Drive in countershaft front bearing (1) using bearing

puller, special tool and hydraulic press.

Special tool
(A): 09913–76010

Reverse Idle Gear Assembly Disassembly and
Reassembly

S6JB0A5226033

Disassembly

1) Drive out reverse idle gear shaft pin using special

tool.

Special tool
(A): 09922–85811

2) Remove reverse idle gear shaft (1), reverse idle gear

washer (2), reverse idle gear (3) and reverse idle
gear needle bearing (4) from reverse idle gear case
(5).

1.50 mm (0.059 in.)

1.68 mm (0.066 in.)

1.59 mm (0.063 in.)

2

1

3

(A)

I5JB0B520092-02

I5JB0B520093-01

(A)

1

I5JB0B520094-02

(A)

I5JB0B520095-01

1

2

2

3

4

5

I5JB0B520109-01

Manual Transmission/Transaxle: For Diesel Engine Model 5B-70

Reassembly

1) Apply oil to reverse idle gear needle bearing (1), and

then install reverse idle gear shaft (2), washer (3),
needle bearing and reverse idle gear (4) to reverse
idle gear case (5).

2) Drive in reverse idle gear shaft pin using special tool.

Special tool
(A): 09922–85811

Countershaft and Reverse Idle Gear Inspection

S6JB0A5226026

• Check chamfered teeth of gear for damage and

excessive wear, and replace as necessary.

• Check spline portions and replace parts if excessive

wear is found.

• Check bearing for smooth rotation and replace it if

abnormality is found.

Manual Transmission Adapter Case
Disassembly and Assembly

S6JB0A5226030

Disassembly
Remove oil seal (1) from adapter case using special tool.

Special tool
(A): 09913–50121

Assembly

1) Install new oil seal (1) to adapter case (2) facing its

spring side upward in figure using special tool and
hammer and then apply grease to oil seal lip.

Special tool
(A): 09913–75520

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

Installation position oil seal
“a”: 1.5 – 2.5 mm (0.059 – 0.098 in.)

2

3

3

4

1

5

I5JB0B520110-01

(A)

I5JB0B520095-01

(A)

1

I5JB0A520086-01

I5JB0B520098-01