Suzuki Grand Vitara JB416 / JB420. Manual — part 251
5A-138 Automatic Transmission/Transaxle:
09926–96510
09926–98310
Spring compressor
Clutch spring compressor
09926–98320
09926–98390
Spring compressor No. 1 set
Remover
09927–66520
09944–88210
Oil pump remover
Bearing housing installer
SUZUKI scan tool
—
This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )
Manual Transmission/Transaxle: 5B-1
Transmission / Transaxle
Manual Transmission/Transaxle
General Description
Manual Transmission Construction
S5JB0A5201001
The manual transmission consists of the input shaft, output 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, 3rd and 4th speeds are for speed reduction drive, 5th speed is for direct drive. The low speed (1st and
2nd) synchronizer is mounted on the countershaft and engaged with the countershaft 1st or 2nd gear. The high speed
(3rd and 4th) synchronizer is mounted on of the input shaft and engaged with the input shaft 3rd and 4th gear. The 5th
speed synchronizer is mounted on the input shaft and engaged with the output shaft. 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.
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.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
I5JB0A520017-02
1. Input shaft
7. 3rd gear
13. Countershaft
2. Transmission front case
8. Gear shift shaft
14. 2nd gear
3. Reverse idler gear
9. Output shaft gear
15. Transmission rear case
4. Reverse shaft
10. Adapter case
16. Low speed synchronizer hub
5. 4th gear
11. Output shaft
17. 1st gear
6. High speed synchronizer hub
12. 5th speed synchronizer hub
18. Reverse gear
5B-2 Manual Transmission/Transaxle:
Diagnostic Information and Procedures
Manual Transmission Symptom Diagnosis
S5JB0A5204001
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 output 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
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.
Manual Transmission/Transaxle: 5B-3
Repair Instructions
Manual Transmission Assembly Components
S5JB0A5206001
6
9
19
20
21
10
18
5
A
3
8
4
27
OIL
1217G
1217G
2
1
24
1322
23
22
25
26
17
16
15
12
11
28
29
13
14
A
30
31
32
33
7
1217G
OIL
1217G
(a)
(a)
(a)
(a)
(a)
(a)
(a)
34
34
34
35
1217G
37
36
38
1217G
(a)
(a)
(c)
(c)
(c)
(c)
I5JB0A520018-04
1. Transmission front case
: Apply sealant 99000-31260 to mating
surface of front case and rear case.
15. Low gear shift inverse lever
29. 5th speed synchronizer lever
2. Transmission rear case
: Apply sealant 99000-31260 to mating
surface of rear case and adapter case.
16. Reverse gear shift lever
30. 5th speed synchronizer sleeve
3. Adapter case
17. Reverse shift locating
31. 5th speed synchronizer ring
4. Gear shift lever front case assembly
: Apply sealant 99000-31260 to mating
surface of rear case and gear shift lever
front case assembly.
18. O-ring
32. Input shaft needle bearing
5. Adapter case oil seal
: Apply grease 99000-25010 to oil seal lip.
19. Back up light switch
33. Output shaft assembly
6. Adapter case bolt
20. Oil filler plug
: Apply sealant 99000-31260 to all around
thread part of bolt.
34. Transmission to engine bolt
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