Suzuki Grand Vitara JB416 / JB420. Manual — part 258

5B-28 Manual Transmission/Transaxle:

Countershaft and Reverse Idle Gear Inspection

S5JB0A5206020

• Using micrometer, check diameter of countershaft (1)

and needle bush (2) as shown. If measured value is
out of specification, replace counter and/or bush.

Countershaft diameter (standard)

• Measure width “a” of low speed gear shift fork and

groove width “b” of low speed gear synchronizer
sleeve and then calculate clearance “c” as follows:

If clearance exceeds limit, replace fork bush (1) and
sleeve.

Clearance “c” between fork and sleeve
Standard: 0.3 – 0.5 mm (0.012 – 0.020 in.)
Limit: 1.0 mm (0.039 in.)

• Check clearance “a” between synchronizer ring (2)

and gear (1), key slot width “b” in synchronizer ring
and each chamfered tooth of gear and synchronizer
ring and replace with new one, if necessary. Also,
check gear tooth.

Clearance “a” between synchronizer ring and
gear (Countershaft) (1st and 2nd)
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)

Key slot width “b” (1st and 2nd synchronizer ring)
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)

• Using cylinder gauge (1), check inside diameter of

countershaft 1st and 2nd gears (2). If measured value
exceeds specification, replace countershaft 5th gear.

Countershaft 1st and 2nd gears diameter
Standard: 40.000 – 40.025 mm (1.5748 – 1.5757 in.)

Measuring

portion

Standard

“a”

25.002 – 25.015 mm

(0.9843 – 0.9848 in.)

“b”

27.987 – 28.000 mm

(1.1019 – 1.1023 in.)

“c”

27.987 – 28.000 mm

(1.1019 – 1.1023 in.)

“d”

30.959 – 30.975 mm

(1.2189 – 1.2194 in.)

“e”

34.975 – 34.991 mm

(1.3770 – 1.3775 in.)

“f”

30.002 – 30.015 mm

(1.1812 – 1.1816 in.)

“g”

28.000 – 28.013 mm

(1.1023 – 1.1028 in.)

“h”

34.975 – 34.991 mm

(1.3770 – 1.3776 in.)

Clearance “c”

=

“b”

–

“a”

“c”

“d”

“e”

“f”

“g”

“h”

“b”

“a”

1

2

I5JB0A520078-01

1

“a”

“b”

I5JB0A520055-01

I5JB0A520079-01

IYSQ01522122-01

Manual Transmission/Transaxle: 5B-29

• Check oil clearance between reverse idle gear (2) and

shaft (1) measuring inside diameter “a” of gear and
diameter “b” of shaft and calculate as follows:

If clearance exceeds limit, replace gear and shaft.

Oil clearance “c” between reverse idle gear and
shaft
Standard: 0.016 – 0.045 mm (0.0006 – 0.0018 in.)
Limit: 0.13 mm (0.005 in.)

• Check clearance between reverse idle gear (2) and

lever (1) of reverse gear shift link.
If clearance exceeds limit, replace gear and lever.

Clearance between reverse idle gear and lever
Standard: 0.05 mm – 0.35 mm (0.002 – 0.014 in.)
Limit: 0.5 mm (0.020 in.)

Output Shaft Disassembly and Assembly

S5JB0A5206021

Disassembly

1) Remove output shaft rear snap ring.
2) Apply bearing puller to output shaft front bearing (1),

and drive out output shaft front bearing, output shaft
gear (2) and output shaft rear bearing (3) all at once
from output shaft using press.

Assembly

1) Clean all components thoroughly, inspect them for

any abnormality and replace with new ones as
necessary.

2) Put front bearing (1) onto output shaft facing groove

(4) side to output shaft gear (2) and drive in output
shaft front bearing, output shaft gear and output
shaft rear bearing (3) all together using special tool
and hammer.

Special tool
(A): 09940–51710

3) Install new output shaft rear snap ring.

Output Shaft Inspection

S5JB0A5206035

Check clearance “a” between ring (2) and output shaft
(1), each chamfered teeth of gear, ring and sleeve, then
determine parts replacement.

Clearance between synchronizer ring and output
shaft
Standard “a”: 1.0 - 1.4 mm (0.040 - 0.055 in.)
Service limit “a”: 0.5 mm (0.020 in.)

Clearance “c”

=

“b”

–

“a”

IYSQ01522123-01

1

2

I5JB0A520080-01

3

2

1

I5JB0A520081-01

(A)

3

2

1

4

I5JB0A520082-01

“a”

1

2

I5JB0A520083-01

5B-30 Manual Transmission/Transaxle:

Manual Transmission Front Case Disassembly
and Assembly

S5JB0A5206022

Disassembly
Remove pump seal (1) and oil seal (2) from front case
using special tools.

Special tool
(A): 09941–64511
(B): 09930–30104

Assembly

1) Set new oil seal to front case with its spring side

facing rear case side.

2) Install oil seal until it becomes flush with case

surface using special tool and hammer and apply
grease to oil seal lip.

Special tool
(A): 09940–51710

: Grease 99000–25010 (SUZUKI Super Grease A)

3) Install pump seal to front case using special tool and

hammer.

Special tool
(A): 09913–75810

Manual Transmission Adapter Case
Disassembly and Assembly

S5JB0A5206023

Disassembly
Remove oil seal (1) from adapter case using special tool.

Special tool
(A): 09913–50121

Assembly

1) Set new oil seal to adapter case with its spring side

facing rear case side.

2) Install oil seal until it becomes flush with case

surface using special tool and hammer and apply
grease to oil seal lip.

Special tool
(A): 09913–85210

: Grease 99000–25010 (SUZUKI Super Grease A)

(B)

(A)

1

1

2

I5JB0A520084-02

(A)

I5JB0A520085-02

(A)

I5JB0A520088-01

(A)

1

I5JB0A520086-01

(A)

I5JB0A520087-01

Manual Transmission/Transaxle: 5B-31

Specifications

Tightening Torque Specifications

S5JB0A5207001

NOTE
The specified tightening torque is also described in the following.
“Manual Transmission Assembly Components”
“Gear Shift Control Lever Rear Case Assembly Components”
“Gear Shift Lever Front Case Assembly Components”
“Gear Shift Shaft and Fork Components”
“Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components”

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

S5JB0A5208001

NOTE
Required service material is also described in the following.
“Manual Transmission Assembly Components”
“Gear Shift Control Lever Rear Case Assembly Components”
“Gear Shift Lever Front Case Assembly Components”
“Gear Shift Shaft and Fork Components”
“Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components”

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

)

Control lever locating bolt

9

0.9

6.5

)

Case cover bolt

10

1.0

7.5

)

Control lever boot cover bolt

12

1.2

9.0

)

Back up light switch

23

2.3

17.0

)

Plate bolt

23

2.3

17.0

)

Control shaft joint nut

18

1.8

13.0

)

/ )

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

)

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

)

/ )