Suzuki Grand Vitara JB416 / JB420. Manual — part 257

5B-24 Manual Transmission/Transaxle:

6) Drive in high speed synchronizer assembly (1) using

special tool and hammer.

NOTE

• While press-fitting sleeve & hub, make

sure that synchronizer ring key slots (2)
are aligned with keys in sleeve & hub
assembly.

• Check free rotation of 4th gear after press

fitting sleeve & hub assembly.

Special tool
(A): 09913–84510

7) Check 4th gear (1) thrust clearance by using

thickness gauge. If clearance is out of specification,
repress-fit or replace defective part.

4th gear thrust clearance
“a”: 0.10 – 0.25 mm (0.004 – 0.010 in.)

8) Apply oil to high speed gear needle bearing, and

then install 3rd gear bush (1), high speed gear
needle bearing (2) and 3rd gear (3).

9) Press-fit 5th speed synchronizer hub (1) using

special tool and hammer.

Special tool
(A): 09913–84510

10) Check 3rd gear (1) thrust clearance by using

thickness gauge. If clearance is out of specification,
repress-fit or replace defective part.

3rd gear thrust clearance
“a”: 0.10 – 0.25 mm (0.004 – 0.010 in.)

(A)

1

2

I5JB0A520061-01

“a”

1

I5JB0A520062-01

4. 4th gear

I5JB0A520063-01

(A)

1

I5JB0A520064-01

“a”

1

I5JB0A520065-01

Manual Transmission/Transaxle: 5B-25

11) Tighten input shaft 5th hub nut to specified torque in

the same manner as step 4) of “Input Shaft
Disassembly”.

CAUTION

!

Do not hold spline, gear teeth or abrasived
surface of shaft with vise through “V” blocks
or the like, otherwise shaft components may
be damaged.

Tightening torque
Input shaft 5th hub nut: 210 N·m (21.0 kgf-m,
152.0 lb-ft)

12) Caulk input shaft 5th hub nut (2) using caulking tool.
13) Drive in new input shaft union (1) using puller and

hydraulic press.

Countershaft Disassembly and Assembly

S5JB0A5206019

Disassembly

1) Remove countershaft rear bearing (1) using bearing

puller, metal stick (2) and hydraulic press.

2) Hold hatched area (5) of countershaft assembly (1)

with “V” blocks (4) on vise (2) or the like to stop
rotation of shaft, undo caulking and countershaft
front bearing nut (3).

CAUTION

!

Do not hold spline, gear teeth or abrasived
surface of shaft with “V” blocks on vise or
the like, otherwise shaft may be damaged.

3) Apply bearing puller to 2nd gear (1), and drive out

countershaft front bearing (2), countershaft reverse
gear (3), 1st gear (4), countershaft gear needle
bearings, countershaft low needle bearing bush, low
speed synchronizer assembly (5) and 2nd gear all at
once from countershaft using metal stick (6) and
hydraulic press.

CAUTION

!

To avoid gear teeth from being damaged,
support 2nd gear at flat side of bearing puller.

1

2

I5JB0A520066-01

1

2

I5JB0A520067-01

5

1

2

3

4

I5JB0A520068-01

2

1

6

3

4

5

I5JB0A520069-01

5B-26 Manual Transmission/Transaxle:

Assembly

1) Clean all components thoroughly, inspect them for

any abnormality and replace with new ones as
necessary.

2) To ensure lubrication, air blow oil holes (1) and make

sure that they are free from any obstruction.

3) Drive in countershaft rear bearing (1) using special

tool and hammer.

Special tool
(A): 09913–84510

4) Apply oil to countershaft gear needle bearing (6),

and then install needle bearing, 2nd gear (5) and low
speed synchronizer ring (7).

5) Assemble synchronizer sleeve (4) and hub (3) as

follows.
a) Fit low speed synchronizer sleeve to hub in

specified direction as shown in figure.

b) Insert 3 keys (2) to hub.
c) Set springs (1) at specified position as shown in

figure.

Synchronizer key installation position
: A = B

6) Drive in low speed synchronizer assembly (1) using

special tool and hammer.

NOTE

• While press-fitting sleeve & hub, make

sure that synchronizer ring key slots (2)
are aligned with keys in sleeve & hub
assembly.

• Check free rotation of 2nd gear after press-

fitting sleeve & hub assembly.

Special tool
(A): 09913–84510

1

I5JB0A520070-01

1

(A)

I5JB0A520071-01

[A]: 1st gear side

C: Key way
D: Chamfered side

I5JB0A520072-01

1

2

(A)

I5JB0A520073-01

Manual Transmission/Transaxle: 5B-27

7) Check 2nd gear (1) thrust clearance by using

thickness gauge. If clearance is out of specification,
repress-fit or replace defective part.

2nd gear thrust clearance
“a”: 0.10 – 0.25 mm (0.004 – 0.010 in.)

8) Apply oil to countershaft gear needle bearing, and

then countershaft low needle bush, needle bearing
and 1st gear (1) to countershaft.

9) Press-fit countershaft reverse gear (2) using special

tool and hammer.

Special tool
(A): 09913–80113

10) Press-fit countershaft front bearing (1) using special

tool and hammer.

Special tool
(A): 09913–84510

11) Check low gear (1) thrust clearance by using

thickness gauge. If clearance is out of specification,
repress-fit or replace defective part.

Low gear thrust clearance
“a”: 0.10 – 0.25 mm (0.004 – 0.010 in.)

12) Tighten countershaft front bearing nut to specified

torque while locking counter shaft in the same
manner as step 2) of “Disassembly” under
“Countershaft Disassembly and Assembly”.

CAUTION

!

Do not hold spline, gear teeth or abrasived
surface of shaft with vise through “V” blocks
or the like, otherwise shaft may be damaged.

Tightening torque
Countershaft front bearing nut: 210 N·m (21.0
kgf-m, 152.0 lb-ft)

13) Caulk countershaft front bearing nut using caulking

tool and hammer.

1

“a”

I5JB0A520074-01

1

(A)

2

I5JB0A520075-01

1

(A)

I5JB0A520076-01

“a”

1

I5JB0A520077-01