Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 346
5B-31 Manual Transmission/Transaxle: For Petrol Engine Model
• Check oil clearance between reverse idle gear (2) and
shaft (1) measuring inside diameter “a” of gear and
diameter “b” of shaft and calculate as follows:
If clearance exceeds limit, replace gear and shaft.
Oil clearance “c” between reverse idle gear and
shaft
Standard: 0.016 – 0.045 mm (0.0006 – 0.0018 in.)
Limit: 0.13 mm (0.005 in.)
• Check clearance between reverse idle gear (2) and
lever (1) of reverse gear shift link.
If clearance exceeds limit, replace gear and lever.
Clearance between reverse idle gear and lever
Standard: 0.05 mm – 0.25 mm (0.002 – 0.010 in.)
Limit: 0.5 mm (0.020 in.)
Output Shaft Disassembly and Assembly
S6JB0A5216027
Disassembly
1) Remove output shaft rear snap ring.
2) Apply bearing puller to output shaft front bearing (1),
and drive out output shaft front bearing, output shaft
gear (2) and output shaft rear bearing (3) all at once
from output shaft using press.
Assembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) Put front bearing (1) onto output shaft facing groove
(4) side to output shaft gear (2) and drive in output
shaft front bearing, output shaft gear and output
shaft rear bearing (3) all together using special tool
and hammer.
Special tool
(A): 09940–51710
3) Install new output shaft rear snap ring.
Output Shaft Inspection
S6JB0A5216028
Check clearance “a” between ring (2) and output shaft
(1), each chamfered teeth of gear, ring and sleeve, then
determine parts replacement.
Clearance between synchronizer ring and output
shaft
Standard “a”: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit “a”: 0.5 mm (0.020 in.)
Clearance “c”
=
“b”
–
“a”
IYSQ01522123-01
1
2
I5JB0A520080-01
3
2
1
I5JB0A520081-01
(A)
3
2
1
4
I5JB0A520082-01
“a”
1
2
I5JB0A520083-01
Manual Transmission/Transaxle: For Petrol Engine Model 5B-32
Manual Transmission Front Case Disassembly
and Assembly
S6JB0A5216029
Disassembly
Remove pump seal (1) and oil seal (2) from front case
using special tools.
Special tool
(A): 09941–64511
(B): 09930–30104
Assembly
1) Set new oil seal to front case with its spring side
facing rear case side.
2) Install oil seal until it becomes flush with case
surface using special tool and hammer and apply
grease to oil seal lip.
Special tool
(A): 09940–51710
: Grease 99000–25010 (SUZUKI Super Grease A)
3) Install pump seal to front case using special tool and
hammer.
Special tool
(A): 09913–75810
Manual Transmission Adapter Case
Disassembly and Assembly
S6JB0A5216030
Disassembly
Remove oil seal (1) from adapter case using special tool.
Special tool
(A): 09913–50121
Assembly
1) Set new oil seal to adapter case with its spring side
facing rear case side.
2) Install oil seal until it becomes flush with case
surface using special tool and hammer and apply
grease to oil seal lip.
Special tool
(A): 09913–85210
: Grease 99000–25010 (SUZUKI Super Grease A)
(B)
(A)
1
1
2
I5JB0A520084-02
(A)
I5JB0A520085-02
(A)
I5JB0A520088-01
(A)
1
I5JB0A520086-01
(A)
I5JB0A520087-01
5B-33 Manual Transmission/Transaxle: For Petrol Engine Model
Extension Case Assembly Components
S6JB0A5216032
13
14-1
5
12
1
7
9
15
8
(a)
(a)
1217G
10
1217G
1217G
OIL
5
OIL
6
OIL
4
A
11
(a)
4
A
2
16
(b)
14-2
(b)
17
3
I6JB0A521001-02
1. Front extension case
12. Extension to transmission bolt
2. Intermediate shaft
13. Breather hose
3. Rear extension case
14-1. Damper (with bracket)
4. Oil seal
: Apply grease 99000-25010 to oil seal lip.
14-2. Damper (without bracket)
5. Bearing
15. Damper bracket (if equipped)
6. Needle bearing
16. Damper nut
7. Hook
17. Damper bolt
8. Hook bolt
: 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
9. Oil filler plug
: Apply sealant 99000-31260 to plug thread.
: 50 N
⋅m (5.0 kgf-m, 36.5 lb-ft)
10. Oil drain plug
: Apply sealant 99000-31260 to plug thread.
: Do not reuse.
11. Extension case bolt
: Apply transmission oil.
Manual Transmission/Transaxle: For Petrol Engine Model 5B-34
Extension Case Assembly Removal and
Installation
S6JB0A5216033
Removal
Remove extension case assembly referring to “Manual
Transmission Assembly Dismounting and Remounting:
For Petrol Engine Model”.
Installation
Reverse removal procedure for installation of extension
case assembly, noting the following points.
• Extension to transmission bolt: 23 N
⋅m (2.3 kgf-m,
17.0 lb-ft)
• Fill gear oil to extension case referring to “Extension
Case Oil Change: For Petrol Engine Model”.
Extension Case Disassembly and Reassembly
S6JB0A5216034
Disassembly
1) Remove rear extension case and damper with
bracket (if equipped) from front extension case.
2) Disassemble rear extension case (2) as follows, if
necessary.
a) Remove oil seal (3) from rear extension case
using flat end rod or the like.
b) Remove needle bearing (1) using special tools.
Special tool
(A): 09913–76010
(B): 09944–66020
3) Remove intermediate shaft from front extension
case.
4) Remove oil seal from front extension case using flat
end rod or the like, if necessary.
5) Remove intermediate front bearing and/or
intermediate rear bearing using press (1) and
bearing puller (2), if necessary.
Reassembly
1) Install intermediate front bearing (1) and/or
intermediate rear bearing (2) using press (3) and
bearing puller (4).
2) Install oil seal (1) to front extension case (2) until it
become flush with case using special tool, and then
apply grease to oil seal lip.
NOTE
When installing oil seal, face its spring side
inward.
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Special tool
(A): 09951–46010
(A)
(B)
2
3
1
I6JB01520003-01
1
2
I6JB01520004-01
3
2
4
1
I6JB01520005-01
1, “A”
(A)
2
I6JB01520006-01
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