Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 348
5B-39 Manual Transmission/Transaxle: For Diesel Engine Model
For Diesel Engine Model
General Description
Manual Transmission Construction
S6JB0A5221001
The manual transmission consists of the input shaft, main shaft, countershaft and reverse idle gear shaft which are
installed in the die-cast aluminum alloy case. This transmission provides five forward speeds and one reverse speed.
The 1st, 2nd and 3rd speeds are for speed reduction drive, 4th speed is for direct drive 5th speed is for speed
increasing drive. The low speed (1st and 2nd) synchronizer is mounted on the main shaft and engaged with the main
shaft 1st or 2nd gear. The high speed (3rd and 4th) synchronizer is mounted on of the main shaft and engaged with
the main shaft 3rd gear or input shaft 4th gear. The 5th & reverse synchronizer is mounted on the main shaft and
engaged with the main shaft 5th or reverse gear. The gear shift lever case is located at the upper behind the
transmission case and has a cam which prevents direct gear shifting from the 5th speed gear into the reverse gear.
The double cone synchronizing mechanism is provided to 1st gear synchromesh. The triple cone synchronizing
mechanism is provided to 2nd and 3rd gear synchromesh.
As the die-cast aluminum alloy case are sealed with liquid type gasket, it is necessary to use genuine sealant or its
equivalent on its mating surface when reassembling them. Also, the case fastening bolts must be tightened to
specified torque by means of the torque wrench and tightening over or below the specified torque should be avoided.
The description under “Repair Instructions” covers the transfer partially which is next to the transmission as well, but
their gear boxes are independent and each of them has its own drain and filler plugs for the oil change or the level
check.
I5JB0B520001-01
1. Input shaft
6. 3rd gear
11. 5th & reverse synchronizer hub
16. Rear case
2. Transmission front case
7. 2nd gear
12. Main shaft
17. Reverse idle gear
3. Input shaft bearing retainer
8. Low speed synchronizer hub
13. Reverse shift shaft
18. Reverse idle gear shaft
4. 4th gear
9. 1st gear
14. Adapter case
19. Reverse idle gear case
5. High speed synchronizer hub
10. Reverse gear
15. Countershaft
Manual Transmission/Transaxle: For Diesel Engine Model 5B-40
Diagnostic Information and Procedures
Manual Transmission Symptom Diagnosis
S6JB0A5224001
Condition
Possible cause
Correction / Reference Item
Gear slipping out of mesh Worn shift fork shaft
Replace.
Worn shift fork or synchronizer sleeve
Replace.
Weak or damaged locating spring
Replace.
Worn bearings on input shaft,
countershaft or main shaft
Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Missing or disengagement of snap
ring(s)
Install or replace.
Gears refusing to
disengage
Weakened or broken synchronizer key
spring
Replace.
Distorted shift shaft or shift fork
Replace.
Hard shifting
Improper clutch pedal free travel
Replace pedal arm and/or clutch master
cylinder.
Distorted or broken clutch disc
Replace.
Damaged clutch pressure plate
Replace clutch cover.
Air in clutch hydraulic system
Bleed air.
Fluid leakage from clutch fluid line
Locate leaking point and repair.
Worn synchronizer ring
Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Distorted shift shaft
Replace.
Noise
Inadequate or insufficient lubricant
Replenish.
Damaged or worn bearing(s)
Replace.
Damaged or worn gear(s)
Replace.
Damaged or worn synchronizer ring
Replace.
Damaged or worn chamfered tooth on
sleeve or gear
Replace.
5B-41 Manual Transmission/Transaxle: For Diesel Engine Model
Repair Instructions
Manual Transmission Assembly Components
S6JB0A5226001
25
21
23
21
20
19
18
14
13
17
41
40
39
3
11
10
36
27
30
(h)
1
15
(c)
26
35
(g)
31
(b)
16
16
33
(e)
42
6
(a)
8
(f)
16
31
(b)
7
(b)
7
(b)
38
(d)
37
(d)
34
(g)
29
(h)
24
9
4
9
2
32
12
5
12
28
27
27
22
(j)
I5JB0B520099-02
1. Transmission front case
: Apply sealant 99000-31110 to mating
surface of front case and rear case.
19. Reverse shift limit cam spring
37. Reverse idle gear case No.1 bolt
2. Transmission rear case
: Apply sealant 99000-31110 to mating
surface of rear case and adapter case.
20. Reverse shift shaft
38. Reverse idle gear case No.2 bolt
3. Adapter case
21. Reverse idle gear washer
39. 5th & reverse gear shift yoke
Manual Transmission/Transaxle: For Diesel Engine Model 5B-42
4. Gear shift lever case assembly
: Apply sealant 99000-31110 to mating
surface of gear shift lever case assembly
and rear case.
22. Reverse idle gear needle bearing
40. High speed gear shift yoke
5. Adapter case oil seal
: Apply grease 99000-25010 to oil seal lip.
23. Reverse idle gear
41. Low speed gear shift yoke
6. Adapter case No.1 bolt
24. Reverse idle gear case
: Apply sealant 99000-31110 to mating
surface of reverse idle gear case and rear
case.
42. Input shaft bearing retainer oil
seal
: Apply grease 99000-25010 to oil
seal lip.
7. Adapter case No.2 bolt
25. Reverse idle gear shaft
: 54 N
⋅m (5.4 kgf-m, 39.0 lb-ft)
8. Gear shift lever case bolt
26. Back up light switch
: 45 N
⋅m (4.5 kgf-m, 32.5 lb-ft)
9. Select return bolt
: Apply sealant 99000-31110 to all around
thread part of bolt
27. Washer
: 22 N
⋅m (2.2 kgf-m, 16.0 lb-ft)
10. Select return low speed spring (short)
28. Back up light switch pin
: Apply grease 99000-25010 to end of pin.
: 25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
11. Select return 5th & reverse spring (long)
29. Oil level/filler plug
: 26 N
⋅m (2.6 kgf-m, 19.0 lb-ft)
12. Select guide pin
30. Oil drain plug
: 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
13. Oil gutter
31. Transmission front case bolt
: 55 N
⋅m (5.5 kgf-m, 40.0 lb-ft)
14. Rear bearing plate
32. Input shaft bearing retainer
: Apply sealant 99000-31110 to mating
surface of input shaft bearing retainer and
front case.
: 35 N
⋅m (3.5 kgf-m, 25.5 lb-ft)
15. Rear bearing plate bolt
33. Input shaft bearing retainer bolt
: 39 N
⋅m (3.9 kgf-m, 28.5 lb-ft)
16. Pin
34. Transmission to engine bolt
: Do not reuse.
17. Gear shift & select lever assembly
35. Transmission to engine nut
: Apply transmission oil.
18. Reverse shift limit cam
36. Input shaft, main shaft & countershaft
assembly
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