Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 340
5B-7 Manual Transmission/Transaxle: For Petrol Engine Model
Gear Shift Shaft and Fork Components
S6JB0A5216004
1322
5
6
7
A
A
6
4
7
A
A
6
7
A
A
6
7
A
A
1
2
3
8
8
8
(a)
1322
5
(a)
1322
5
(a)
1322
5
(a)
I5JB0A520002-02
1. Low speed gear shift shaft
4. Low speed gear shift fork
7. Gear shift shaft ball
: Apply grease 99000-25010 to ball.
2. High speed gear shift fork
5. Gear shift locating bolt
: Apply thread lock 99000-32110 to bolt thread.
8. Gear shift fork bush
3. 5th & reverse gear shift fork
: Never disassemble.
6. Gear shift locating spring
: Apply grease 99000-25010 to spring.
: 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
Manual Transmission/Transaxle: For Petrol Engine Model 5B-8
Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components
S6JB0A5216005
6
4
3
2
18
24
25
34
35
37
36
26
27
28
30
31
29
32
33
30
29
19
20
21
22
5
1
7
9
8
10
11
12
9
8
13
14
17
23
[A]
[B]
[C]
OIL
15
16
OIL
OIL
OIL
(a)
(a)
38
39
40
OIL
OIL
OIL
OIL
OIL
I6JB01520012-01
[A]: Input shaft assembly
14. 5th speed synchronizer hub
30. Low speed synchronizer spring
[B]: Output shaft assembly
15. High speed gear needle bearing
31. Low speed synchronizer key
[C]: Countershaft assembly
16. Input shaft 3rd gear bush
32. Low speed synchronizer hub
1. Snap ring
17. Input shaft 5th hub nut
33. Low speed synchronizer sleeve
2. Input shaft front bearing
18. Output shaft
34. Countershaft gear needle bearing
3. Input shaft front bearing circlip
19. Output shaft front bearing
35. 2nd gear
4. Input shaft
20. Output shaft gear
36. Countershaft
5. Input shaft union
21. Output shaft rear bearing
37. Countershaft rear bearing
5B-9 Manual Transmission/Transaxle: For Petrol Engine Model
Manual Transmission Oil Change
S6JB0A5216006
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If
leakage exists, correct or repair it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.
3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transmission oil drain plug (a): 23 N·m (2.3 kgf-
m, 17.0 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.)
Manual transmission oil capacity
Reference: 1.9 liters (4.0/3.3 US/Imp. pt)
7) Apply sealant to thread of filler plug, and then tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Oil filler plug (b): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
6. High speed gear needle bearing
22. Output shaft rear snap ring
38. 5th speed synchronizer sleeve
7. 4th gear
23. Countershaft front bearing nut
39. 5th speed synchronizer lever
8. High speed synchronizer ring
24. Countershaft front bearing
40. 5th speed synchronizer ring
9. High speed synchronizer spring
25. Countershaft reverse gear
: 210 N
⋅m (21.0 kgf-m, 152.0 lb-ft)
10. High speed synchronizer sleeve
26. Countershaft low needle bush
: Do not reuse.
11. High speed synchronizer key
27. Countershaft gear needle bearing
: Apply transmission oil.
12. High speed synchronizer hub
28. 1st gear
13. 3rd gear
29. Low speed synchronizer ring
2, (b), “A”
1, (a), “A”
I5JB0A520020-01
I5JB0A520022-02
80W-90
Temperature
-30
C
o
F
o
-20
-10
0
10
20
30
40
-22
-4
14
32
50
68
86
104
75W-85, 75W-90
[A]
I5JB0A520021-02
Manual Transmission/Transaxle: For Petrol Engine Model 5B-10
Extension Case Oil Level Check
S6JB0A5216036
1) Lift up vehicle and check oil leakage.
2) Remove oil level / filler plug (1) and check oil level is
lower end of oil level / filler plug hole (2).
If oil level is not lower end of oil level / filler plug hole,
add specified oil up to plug hole.
Extension Case Oil Change
S6JB0A5216031
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If
leakage exists, correct or repair it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.
3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Extension case oil drain plug (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
NOTE
If water or rust is mixed in drained oil, be
sure to check breather hose of extension
case.
6) Pour new specified oil until oil level reaches bottom
of oil filler plug hose (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.)
Extension case oil capacity (Reference)
0.4 liters (0.8/0.7 US/lmp. pt)
7) Apply sealant to thread of filler plug, and then tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Extension case oil filler plug (b): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
1
I6JB01520016-02
I6JB01520014-01
2, (b), “A”
1, (a), “A”
I6JB01520001-01
I5JB0A520022-02
80W-90
Temperature
-30
C
o
F
o
-20
-10
0
10
20
30
40
-22
-4
14
32
50
68
86
104
75W-85, 75W-90
[A]
I5JB0A520021-02
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