Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 341

5B-11 Manual Transmission/Transaxle: For Petrol Engine Model

Transmission Shift Control Lever Removal and
Installation

S6JB0A5216007

Removal

1) Remove front console box referring to “Console Box

Components in Section 9H”.

2) Lift up boot cover (1), boot (2) and sheet (3).
3) Remove case cover (4) and take out shift control

lever (5) from gear shift lever rear case (6).

Installation

1) Tighten new control lever locating bolts (1) to

specified torque, if removed.

Tightening torque
Control lever locating bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)

2) Apply grease to pivot portions and seat, then install

shift control lever.

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

3) Set shift control lever (2) to gear shift lever rear case.
4) Install case cover (1) to gear shift lever rear case (3).

Tighten case cover bolt to specified torque.

Tightening torque
Case cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)

5) Install sheet, boot (1) with boot cover (2) to floor

panel.

Tightening torque
Control lever boot cover bolt (a): 12 N·m (1.2
kgf-m, 9.0 lb-ft)

6) Install front console box referring to “Console Box

Components in Section 9H”.

Transmission Shift Control Lever Inspection

S6JB0A5216008

• Check transmission shift control lever lower portion

and control lever locating sheet for excessive wear.

• Check boot for damage.
Correct or replace if necessary.

6

4

5

3

1

2

I5JB0A520023-02

“A”

1, (a), “B”

I5JB0A520024-03

3

(a)

1

2

I5JB0A520025-02

2

(a)

1

I5JB0A520027-02

Manual Transmission/Transaxle: For Petrol Engine Model 5B-12

Back Up Light Switch Removal and Installation

S6JB0A5216009

Removal

WARNING

!

Refrain from work while exhaust No.2 pipe is
hot.

NOTE
When replacing switch, use care not to let
dust enter transmission through switch hole.

1) Hoist vehicle and disconnect connector from back up

light switch.

2) Remove back up light switch (1) from transmission

rear case.

Installation
Reverse removal procedure for installation noting the
following.
• Apply oil to new O-ring (1) and then install back up

light switch (2) to transmission rear case.

Tightening torque
Back up light switch (a): 19 N·m (1.9 kgf-m, 14.0
lb-ft)

• Check back up light for proper function with ignition

switch turned ON and reverse position.

Back Up Light Switch Inspection

S6JB0A5216010

Check back up light switch for function using ohmmeter.
If resistance is not as specified below, replace back up
light switch.

Back up light switch specification
Switch ON (Push): Continuity
Switch OFF (Release): No continuity

Gear Shift Control Lever Rear Case Assembly
Removal and Installation

S6JB0A5216011

4WD model
Removal

1) Dismount transmission assembly from vehicle

referring to “Manual Transmission Assembly
Dismounting and Remounting: For Petrol Engine
Model”.

2) Remove gear shift control lever rear case assembly

(1) with plate (2) from transfer case.

1

I5JB0A520005-01

1

2, (a)

I5JB0A520004-01

I5JB0A520006-01

1

2

I5JB0A520007-03

5B-13 Manual Transmission/Transaxle: For Petrol Engine Model

Installation

1) Install gear shift control lever rear case assembly

with its plate to transfer case referring to figure for
proper installing direction of control shaft joint bolt
(2). Tighten plate bolts (1) and control shaft joint nut
(3) to specified torque.

Tightening torque
Plate bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Control shaft joint nut (b): 18 N·m (1.8 kgf-m,
13.0 lb-ft)

2) Remount transmission assembly to vehicle referring

to “Manual Transmission Assembly Dismounting and
Remounting: For Petrol Engine Model”.

2WD model
Removal

1) Dismount transmission assembly from vehicle

referring to “Manual Transmission Assembly
Dismounting and Remounting: For Petrol Engine
Model”.

2) Remove gear shift control lever rear case assembly

(1) with plate (2) from extension case.

Installation

1) Install gear shift control rear case assembly with its

plate to extension case referring to figure for proper
installing direction of control shaft joint bolt (2).
Tighten shift lever bolt (4) and then plate bolts (1)
and control shaft joint nut (3) to specified torque.

Tightening torque
Plate bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Control shaft joint nut (b): 18 N·m (1.8 kgf-m,
13.0 lb-ft)
Shift lever bolt (c): 23 N·m (2.3 kgf-m, 17.0 lb-ft)

2) Remount transmission assembly to vehicle referring

to “Manual Transmission Assembly Dismounting and
Remounting: For Petrol Engine Model”.

Gear Shift Control Lever Rear Case Assembly
Disassembly and Reassembly

S6JB0A5216012

Disassembly and reassembly component parts referring
to “Gear Shift Control Lever Rear Case Assembly
Components: For Petrol Engine Model”.

Gear Shift Control Lever Rear Case Assembly
Inspection

S6JB0A5216013

• Check that gear shift control shaft moves smoothly

without abnormal noise. If abnormality is found,
replace defective part.

• Check bush and boot for damage and deterioration. If

abnormality is found, replace defective part.

1, (a)

2

3, (b)

I5JB0A520008-03

1

2

I6JB0A521003-01

1, (a)

2

3, (b)

4, (c)

I6JB0A521004-01

Manual Transmission/Transaxle: For Petrol Engine Model 5B-14

Gear Shift Lever Front Case Assembly Removal
and Installation

S6JB0A5216014

Removal

1) Dismount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting: For Petrol Engine Model”.

2) Remove gear shift lever front case assembly (1)

from transmission rear case.

Installation

NOTE

• Install gear shift lever front case to

transmission rear case without using
sealant for functional check.

• Install shift control lever and check to

make sure that it shifts smoothly
according to shift pattern as shown in the
figure.

1) Clean mating surface of both rear case and gear

shift lever front case (2), and uniformly apply sealant
to lever 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 gear shift lever front case.

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

2) Install lever case to rear case and then tighten new

lever case bolts (1) to specified torque.

Tightening torque
Gear shift lever front case bolt (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)

3) Connect gear shift shaft (3) of lever case assembly

to gear shift control shaft (4) of gear shift control
lever rear case assembly referring to figure for
proper installing direction of control shaft joint bolt
(5). Tighten control shaft joint nut (6) to specified
torque.

Tightening torque
Control shaft joint nut (b): 18 N·m (1.8 kgf-m,
13.0 lb-ft)

4) Remount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting: For Petrol Engine Model”.

1

I5JB0A520009-03

I5JB0A520010-01

1, (a)

3

5

4

6, (b)

2

“A”

2

I5JB0A520011-04