Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 352

5B-55 Manual Transmission/Transaxle: For Diesel Engine Model

10) Remove rear case to front case bolts (1), then

separate rear case (2) from front case (3) using
special tool.

Special tool
(A): 09912–34510

11) Drive out each gear shift shaft pin using special tool

and then remove each gear shift shaft (1), fork (2),
ball and inter lock pin.

Special tool
(A): 09922–85811

12) Remove input shaft bearing retainer to front case

bolt (1), then separate input shaft bearing retainer (2)
from front case (3).

13) Remove oil seal (1) from input shaft bearing retainer

(2) using flat end rod or the like, if necessary.

14) Remove input shaft front bearing circlip (1) from front

case (3) using snap ring pliers (2).

1

2

3

(A)

1

1

1

I5JB0B520030-01

(A)

1

2

I5JB0B520031-01

3

1

1

1

2

I5JB0B520032-01

1

2

I5JB0B520033-01

1

2

3

I5JB0B520034-01

Manual Transmission/Transaxle: For Diesel Engine Model 5B-56

15) Remove input shaft assembly, main shaft assembly

(1) and countershaft assembly (2) all together from
front case (3) tapping input shaft end by plastic
hammer lightly.

Manual Transmission Unit Reassembly

S6JB0A5226020

1) Assemble input shaft assembly, main shaft assembly

(1) and countershaft assembly (2), and then install
them all together into front case (3).

2) Install new input shaft front bearing circlip (1) to front

case using snap ring pliers (2)

3) Install new oil seal (1) to input shaft bearing retainer

(2) facing its spring side upward in figure using
special tool and hammer and then apply grease to oil
seal lip.

Special tool
(A): 09913–76010

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

Install position oil seal
“a”: 0 – 1.0 mm (0 – 0.0039 in.)

4) Clean mating surfaces of both input shaft bearing

retainer (1) and front case (2), and uniformly apply
sealant to input shaft bearing retainer as shown in
figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, and then mate it with front
case.

“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)

5) Install input shaft bearing retainer to front case with

new bolts. Tighten bolts (3) to specified torque.

Tightening torque
Input shaft bearing retainer bolt (a): 26 N·m (2.6
kgf-m, 19.0 lb-ft)

3

2

1

I5JB0B520035-01

3

2

1

I5JB0B520035-01

1

2

I5JB0B520036-02

I5JB0B520038-01

“A”

1

3, (a)

3, (a)

3, (a)

2

I5JB0B520037-01

5B-57 Manual Transmission/Transaxle: For Diesel Engine Model

6) Install low speed gear shift shaft (1) and low speed

gear shift fork (2) to front case (3).

7) Apply grease to gear shift shaft balls (4), and then

install it to hole of front case (5) between low speed
gear shift shaft and high speed gear shift shaft.

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

8) Install 5th & reverse gear shift fork (1) and high

speed gear shift fork (2) to front case (3).

9) Apply grease to inter lock pin (4), and install it to high

speed gear shift shaft (5), and then install high speed
gear shift shaft to front case.

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

10) Apply grease to gear shift shaft balls (1), and then

install it to hole of front case (2) between high speed
gear shift shaft and 5th & reverse gear shift shaft.

11) Install 5th & reverse gear shift shaft (3) to front case

(4).

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

12) Set new gear shift shaft inner pin (1) and outer pin

(2) facing each gap (“a”, “b”) in the opposite direction
as shown in figure. Drive each gear shift shaft pin by
using special tool.

Special tool
(A): 09922–85811

13) Clean mating surfaces of both front case (1) and rear

case (2), and uniformly apply sealant to front case as
shown in figure by such amount that its section is 1.5
mm (0.059 in.) in diameter, and then mate it with rear
case.

“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)

14) Install front case to rear case. Tighten front case

bolts (3) to specified torque.

Tightening torque
Front case bolt (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)

3

1

2

5

1

4, “A”

I5JB0B520039-01

3

2

1

5

5

4, “A”

I5JB0B520040-03

3

4

3

1, “A”

2

I5JB0B520041-02

“a”

“b”

1

2

(A)

I5JB0B520042-01

1

2

3, (a)

1

3, (a)

3, (a)

3, (a)

1

“A”

I5JB0B520043-02

Manual Transmission/Transaxle: For Diesel Engine Model 5B-58

15) Apply grease to gear shift locating balls (1) and

springs (2), then install them. Apply sealant to gear
shift locating bolts (3), and then tighten bolts to
specified torque.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
“B”: Sealant 99000–31110 (SUZUKI Bond
No.1215)

Tightening torque
Gear shift locating bolt (a): 19 N·m (1.9 kgf-m,
14.0 lb-ft)

16) Install new circlip (1) of main shaft rear bearing to

rear case using snap ring pliers (2).

17) Install reverse shift shaft (1), rear bearing plate (2)

and oil gutter (3) as shown in figure. Tighten rear
bearing plate bolts (4) to specified torque.

Tightening torque
Rear bearing plate bolt (a): 22 N·m (2.2 kgf-m,
16.0 lb-ft)

18) Install reverse shift limit spring (1) and cam (2) to

reverse shift shaft (3), and then hook spring to rear
bearing plate.

19) Set new gear shift shaft inner pin (4) and outer pin

(5) facing each gap (“a”, “b”) in the opposite direction
as shown in figure. Drive gear shift shaft pins by
using special tool.

Special tool
: 09922–85811

20) Install gear shift & select lever assembly (1) and

each gear shift yoke (2).

21) Set new gear shift yoke inner pin (3) and outer pin

(4) facing each gap (“a”, “b”) in the opposite direction
as shown in figure. Drive gear shift yoke pin by using
special tool.

Special tool
(A): 09922–85811

2, “A”

3, “B”, (a)

2, “A”

1,“A”

1, “A”

I5JB0B520044-01

2

1

I5JB0B520045-01

1

2

1

3

4, (a)

4, (a)

2

I5JB0B520046-01

A: Upper side

“a”

“b”

4

5

A

2

3

2

1

3

I5JB0B520047-04

“a”

“b”

3

4

(A)

2

1

I5JB0B520048-02