Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 347
5B-35 Manual Transmission/Transaxle: For Petrol Engine Model
3) Install intermediate shaft with bearings to front
extension case.
4) Assemble rear extension case (2) as follows.
a) Install needle bearing (1) to rear extension case
until it become flush with case using special tool.
Special tool
(A): 09913–75520
b) Install oil seal (1) to rear extension case (2) until
it become flush with case using special tool, and
then apply grease to oil seal lip.
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Special tool
(A): 09913–75510
5) Clean mating surfaces of front extension case (2)
and rear extension case (1), apply sealant to rear
extension case as shown in figure by such amount
that its section is 1.5 mm (0.059 in.) in diameter, and
install rear extension case and damper bracket (3) (if
equipped) to front extension case and then tighten
case bolts (4) to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Extension case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
6) Install damper (1) to damper bracket (4) or rear
extension case (2) and tighten damper nuts (5) or
damper bolts (3) to specified torque.
Tightening torque
Damper bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft)
Damper nut (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft)
Extension Case Assembly Inspection
S6JB0A5216035
• Check needle bearing and bearing contacting surface
for damage. Replace as required.
• Check bearing for smooth rotation and replace it if
abnormality is found.
(A)
1
2
I6JB01520007-01
(A)
1, “A”
2
I6JB01520008-01
1
2
3
1
“A”
4,(a)
I6JB0A521005-01
1
2
3,(a)
2
4
1
5,(b)
I6JB0A521006-01
Manual Transmission/Transaxle: For Petrol Engine Model 5B-36
Specifications
Tightening Torque Specifications
S6JB0A5217001
NOTE
The specified tightening torque is also described in the following.
“Manual Transmission Assembly Components: For Petrol Engine Model”
“Gear Shift Control Lever Rear Case Assembly Components: For Petrol Engine Model”
“Gear Shift Lever Front Case Assembly Components: For Petrol Engine Model”
“Gear Shift Shaft and Fork Components: For Petrol Engine Model”
“Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components: For Petrol
Engine Model”
“Extension Case Assembly Components: For Petrol Engine Model”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.
Special Tools and Equipment
Recommended Service Material
S6JB0A5218001
Fastening part
Tightening torque
Note
N
⋅m
kgf-m
lb-ft
Transmission oil drain plug
23
2.3
17.0
Oil filler plug
23
2.3
17.0
Extension case oil drain plug
23
2.3
17.0
Extension case oil filler plug
23
2.3
17.0
Control lever locating bolt
10
1.0
7.5
Case cover bolt
10
1.0
7.5
Control lever boot cover bolt
12
1.2
9.0
Back up light switch
19
1.9
14.0
Plate bolt
23
2.3
17.0
Control shaft joint nut
18
1.8
13.0
Shift lever bolt
23
2.3
17.0
Gear shift lever front case bolt
23
2.3
17.0
Engine rear mounting No.1 bolt
55
5.5
40.0
Engine rear mounting member bolt
55
5.5
40.0
Engine rear mounting No.2 bolt
55
5.5
40.0
Transmission to engine bolt and nut
85
8.5
61.5
Clutch housing lower plate bolt
11
1.1
8.0
Low gear shift inverse lever bolt
23
2.3
17.0
Transmission case bolt
23
2.3
17.0
Reverse shaft bolt
23
2.3
17.0
Gear shift locating bolt
23
2.3
17.0
Adapter case bolt
23
2.3
17.0
Input shaft 5th hub nut
210
21.0
152.0
Countershaft front bearing nut
210
21.0
152.0
Extension case bolt
23
2.3
17.0
Damper bolt
50
5.0
36.5
Damper nut
50
5.0
36.5
Material
SUZUKI recommended product or Specification
Note
Grease
SUZUKI Super Grease A
P/No.: 99000–25010
Sealant
SUZUKI Bond No.1217G
P/No.: 99000–31260
Thread lock cement
Thread Lock Cement Super 1322
P/No.: 99000–32110
5B-37 Manual Transmission/Transaxle: For Petrol Engine Model
NOTE
Required service material is also described in the following.
“Manual Transmission Assembly Components: For Petrol Engine Model”
“Gear Shift Control Lever Rear Case Assembly Components: For Petrol Engine Model”
“Gear Shift Lever Front Case Assembly Components: For Petrol Engine Model”
“Gear Shift Shaft and Fork Components: For Petrol Engine Model”
“Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components: For Petrol
Engine Model”
“Extension Case Assembly Components: For Petrol Engine Model”
Special Tool
S6JB0A5218002
09900–06106
09913–50121
Snap ring pliers (closing
type)
Oil seal remover
09913–75510
09913–75520
Bearing installer
Bearing installer
09913–75810
09913–76010
Bearing installer
Bearing installer
09913–80113
09913–84510
Bearing installer
Bearing installer
09913–85210
09923–46020
Bearing installer
Joint pipe
09925–78210
09930–30104
Spring pin remover (6 mm)
Sliding shaft
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