Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 350

5B-47 Manual Transmission/Transaxle: For Diesel Engine Model

7) Install oil level/filler plug with new washer, and then

tighten it to specified torque.

Tightening torque
Oil filler plug (b): 35 N·m (3.5 kgf-m, 25.0 lb-ft)

Transmission Shift Control Lever Removal and
Installation

S6JB0A5226007

Removal

1) Remove front console box referring to “Console Box

Components in Section 9H”.

2) Lift up boots cover (1), boot (2) and sheet (3).
3) With gear shift control case cover (4) pushed down

with fingers, turn it to counter clockwise and take out
shift control lever (5).

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)

1, (a)

2, (b)

I5JB0B520006-01

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

5

2

3

1

4

I5JB0B520111-02

“A”

1, (a)

I5JB0B520112-01

Manual Transmission/Transaxle: For Diesel Engine Model 5B-48

3) Set shift control lever (2) to gear shift lever case.
4) With gear shift control case cover (1) pushed down

by hand, turn gear shift control case cover (1) to
clockwise.

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

S6JB0A5226008

• Check transmission shift control lever lower portion

and control lever locating sheet for excessive wear.

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

Back Up Light Switch Removal and Installation

S6JB0A5226009

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), washer and pin

from transmission front case.

Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to back up light switch pin (3) and then

install back up light switch (1), new washer (2) and pin
to transmission front case.

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

Tightening torque
Back up light switch (a): 39 N·m (3.9 kgf-m, 28.5
lb-ft)

• Check back up light for proper function with ignition

switch turned ON and reverse position.

1

2

I5JB0B520113-01

2

(a)

1

I5JB0A520027-02

1

I5JB0B520010-01

2

1, (a)

3, “A”

I5JB0B520011-01

5B-49 Manual Transmission/Transaxle: For Diesel Engine Model

Back Up Light Switch Inspection

S6JB0A5226010

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

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

Gear Shift Lever Case Assembly Removal and
Installation

S6JB0A5226014

Removal

1) Dismount transmission assembly referring to

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

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

transmission adapter case.

Installation

NOTE

• Install gear shift lever case to transmission

adapter 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.

I5JB0B520012-01

1

I5JB0B520013-01

I5JB0A520010-01

Manual Transmission/Transaxle: For Diesel Engine Model 5B-50

1) Clean mating surface of both adapter case and gear

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

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

2) Install lever case to adapter 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) Remount transmission assembly referring to

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

Gear Shift Lever Case Assembly Disassembly
and Reassembly

S6JB0A5226015

Disassembly

1) Remove gear shift case plate.
2) Drive out gear shift arm pin and gear shift lever pin

using special tool, and then disassemble
components parts.

Special tool
(A): 09922–85811

Reassembly

1) Clean all pants thoroughly, inspect them and replace

with new one as required.

2) Assemble components parts referring to “Gear Shift

Lever Case Assembly Components: For Diesel
Engine Model”.

3) Set new gear shift arm inner pin (1) and outer pin (2)

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

Special tool
(A): 09922–85811

1, (a)

2

“A”

I5JB0B520014-02

(A)

(A)

I5JB0B520015-01

“a”

“b”

1

2

(A)

I5JB0B520016-01