Suzuki Grand Vitara JB419. Manual — part 109

Manual Transmission/Transaxle: 5B-12

Gear Shift Lever Case Assembly Removal and
Installation

S5JB0B5206014

Removal

1) Dismount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting”

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.

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”

1

I5JB0B520013-01

I5JB0A520010-01

1, (a)

2

“A”

I5JB0B520014-02

5B-13 Manual Transmission/Transaxle:

Gear Shift Lever Case Assembly Disassembly
and Reassembly

S5JB0B5206015

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”.

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

4) Install gear shift case plate to gear shift lever case

and tighten them to specified torque.

Tightening torque
Gear shift lever case plate screw: 6 N·m (0.6 kgf-
m, 4.5 lb-ft)

Gear Shift Lever Case Assembly Inspection

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• Check that gear shift shaft moves smoothly without

abnormal noise. If abnormality is found, replace
defective part.

• Check bushes and boot for damage and deterioration.

If abnormality is found, replace defective part.

Engine Rear Mounting Replacement

S5JB0B5206017

When replacement of mounting parts are necessary,
torque bolts as specified below.

Tightening torque
Engine rear mounting No.1 bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)
Engine rear mounting member bolt (b): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine rear mounting No.2 bolt (c): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)

(A)

(A)

I5JB0B520015-01

“a”

“b”

1

2

(A)

I5JB0B520016-01

1. Engine rear mounting member

2. Engine rear mounting

I5JB0A520015-01

Manual Transmission/Transaxle: 5B-14

Manual Transmission Assembly Dismounting
and Remounting

S5JB0B5206018

Dismounting

1) Disconnect negative (–) cable of battery.
2) Remove transmission shift control lever referring to

“Transmission Shift Control Lever Removal and
Installation”.

3) Remove turbocharger inlet pipe (1), vacuum pump

(2), engine hanger bracket, throttle body (3), noise
suppressor wire (5) and air intake pipe (4).

CAUTION

!

When removing manual transmission, after
remove turbocharger inlet pipe, noise
suppressor wire and vacuum pump.
Otherwise, heater hoses, noise suppressor
wire and vacuum pump is damaged.

4) Detach engine harness clamps and ground wire

harness from transmission front case.

5) Remove starting motor fastening bolts and

transmission fastening bolts.

6) Disconnect clutch fluid pipe from joint referring to

“Clutch Fluid Pipe and Hose Removal and
Installation in Section 5C in related manual”.

7) Hoist vehicle.
8) Drain oil from transmission and transfer.
9) Remove propeller shafts referring to “Propeller Shaft

Removal and Installation in Section 3D”.

10) Remove exhaust No. 2 pipe.

11) Remove engine under cover.

12) Disconnect the following couplers and release their

harness from clamps.
• CKP sensor
• Back up light switch
• Transfer shift actuator
• 4L/N switch
• Center differential lock switch

13) Remove clutch housing plate (1) and harness

bracket (3).

14) Remove transmission fastening nut and bolts (2).

1

4

2

3

I5JB0B520103-01

5

I5JB0B520017-02

2

2

2

1

3

I5JB0B520105-01

5B-15 Manual Transmission/Transaxle:

15) Apply transmission jack (1) and remove engine rear

mounting member (2) taking off its bolts.

16) After removing mounting member, move rearward

transmission and transfer assemblies placed on jack
and then lower them.

17) Separate gear shift lever case assembly (2) and

transfer assembly (3) from transmission assembly
(1).

Remounting
For remounting, reverse dismounting procedure noting
the following.
• Apply grease to input shaft.

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

• Slant the rear of the engine down, using support

device (1) and install transmission to engine.

• Use specified torques as given below.

Tightening torque
Transmission to engine bolt and nut (a): 55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Engine rear mounting member bolt (b): 55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Clutch housing plate bolt (c): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Engine rear mounting No.2 bolt (d): 55 N·m (5.5
kgf-m, 40.0 lb-ft)

• Set each clamp for wiring and hose securely.
• Install noise suppressor wire (1) at specified position

as shown in figure.

2

1

I5JB0A520029-01

1

2

3

I5JB0B520019-01

“A”

I5JB0A520031-01

I3JA01520024-01

[A]: Forward

2. Installation position (90

°)

(a)

(b)

(b)

(d)

(a)

(c)

(a)

I5JB0B520021-01

2

[A]

1

I5JB0B520020-01