Suzuki Grand Vitara JB419. Manual — part 111

Manual Transmission/Transaxle: 5B-20

12) Set new gear shift shaft inner pin (1) and outer pin

(2) facing each gap (“a”, “b”) in the opposite direction
as shown in figure. Drive each gear shift shaft pin by
using special tool.

Special tool
(A): 09922–85811

13) Clean mating surfaces of both front case (1) and rear

case (2), and uniformly apply sealant to front 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 rear
case.

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

14) Install front case to rear case. Tighten front case

bolts (3) to specified torque.

Tightening torque
Front case bolt (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)

15) Apply grease to gear shift locating balls (1) and

springs (2), then install them. Apply sealant to gear
shift locating bolts (3), and then tighten bolts to
specified torque.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
“B”: Sealant 99000–31110 (SUZUKI Bond
No.1215)

Tightening torque
Gear shift locating bolt (a): 19 N·m (1.9 kgf-m,
14.0 lb-ft)

16) Install new circlip (1) of main shaft rear bearing to

rear case using snap ring pliers (2).

17) Install reverse shift shaft (1), rear bearing plate (2)

and oil gutter (3) as shown in figure. Tighten rear
bearing plate bolts (4) to specified torque.

Tightening torque
Rear bearing plate bolt (a): 22 N·m (2.2 kgf-m,
16.0 lb-ft)

“a”

“b”

1

2

(A)

I5JB0B520042-01

1

2

3, (a)

1

3, (a)

3, (a)

3, (a)

1

“A”

I5JB0B520043-02

2, “A”

3, “B”, (a)

2, “A”

1,“A”

1, “A”

I5JB0B520044-01

2

1

I5JB0B520045-01

1

2

1

3

4, (a)

4, (a)

2

I5JB0B520046-01

5B-21 Manual Transmission/Transaxle:

18) Install reverse shift limit spring (1) and cam (2) to

reverse shift shaft (3), and then hook spring to rear
bearing plate.

19) Set new gear shift shaft inner pin (4) and outer pin

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

Special tool
: 09922–85811

20) Install gear shift & select lever assembly (1) and

each gear shift yoke (2).

21) Set new gear shift yoke inner pin (3) and outer pin

(4) facing each gap (“a”, “b”) in the opposite direction
as shown in figure. Drive gear shift yoke pin by using
special tool.

Special tool
(A): 09922–85811

22) Clean mating surfaces of both rear case (1) and

adapter case (2), and uniformly apply sealant to rear
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 adapter case.

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

23) Install rear case to adapter case. Tighten adapter

case No.1 bolts (3) and new adapter case No.2 bolt
(4) to specified torque.

Tightening torque
Adapter case No.1 bolt (a): 45 N·m (4.5 kgf-m,
32.5 lb-ft)
Adapter case No.2 bolt (b): 54 N·m (5.4 kgf-m,
39.0 lb-ft)

A: Upper side

“a”

“b”

4

5

A

2

3

2

1

3

I5JB0B520047-04

“a”

“b”

3

4

(A)

2

1

I5JB0B520048-02

1

2

3, (a)

4, (b)

3, (a)

1

2

“A”

I5JB0B520049-02

Manual Transmission/Transaxle: 5B-22

24) Clean mating surfaces of both reverse idle gear case

(1) and rear case (2), and uniformly apply sealant to
reverse idle gear 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 rear case.

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

25) Install reverse idle gear case to rear case with new

bolts. Tighten No.1 bolts (3) and No.2 bolts (4) to
specified torque.

Tightening torque
Reverse idle gear case No.1 bolt and No.2 bolt
(a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)

26) Apply grease to select guide pins (1), and then install

select guide pins, select return low speed spring
(short) (2) and select return 5th & reverse spring
(long) (3). Apply sealant to select return bolts, and
then tighten bolts (4) to specified torque.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
“B”: Sealant 99000–31110 (SUZUKI Bond
No.1215)

Tightening torque
Select return bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-
ft)

27) Install buck up light switch (1), new washer and pin

to front case (2) referring to “Back Up Light Switch
Removal and Installation”.

28) Install clutch operating cylinder assembly to

transmission front case referring to “Clutch
Operating Cylinder Assembly Removal and
Installation in Section 5C”.

Locating Spring Inspection

S5JB0B5206021

Check locating springs for deterioration and replace with
new ones if necessary.

Locating spring free length
Standard: 44.6 mm (1.756 in.)
Service limit: 40.1 mm (1.579 in.)

Input Shaft Assembly Disassembly and
Reassembly

S5JB0B5206031

Disassembly

1) Remove input shaft circlip from input shaft using

snap ring pliers.

2) Remove input shaft bearing (1) from input shaft (2)

using bearing puller and hydraulic press.

3, (a)

2

1

4, (a)

3, (a)

1

“A”

I5JB0B520050-01

4, “B”, (a)

4, “B”, (a)

1, “A”

2

3

1, “A”

I5JB0B520051-01

1

2

I5JB0B520052-01

2

1

I5JB0B520053-01

5B-23 Manual Transmission/Transaxle:

Reassembly

1) Clean all components thoroughly, inspect them for

any abnormality and replace with new ones as
necessary.

2) Drive in input shaft bearing (1) onto input shaft facing

groove (2) side to downward in figure (3) using
special tool and hydraulic press.

Special tool
(A): 09913–75520

3) Select circlip (1) that will make thrust clearance “a” of

bearing 0.15 mm (0.006 in) or less and install it.

Available circlip thickness

Input Shaft Inspection

S5JB0B5206032

• Check chamfered teeth of gear for damage and

excessive wear, and replace as necessary.

• Check spline portions and replace parts if excessive

wear is found.

• Check bearing for smooth rotation and replace it if

abnormality is found.

Main Shaft Disassembly

S5JB0B5206022

1) Remove main shaft bearing circlip using snap ring

pliers.

2) Remove main shaft bearing (1) from main shaft (2)

using bearing puller and hydraulic press.

3) Remove circlip (1) using snap ring pliers (2) and then

pull out high speed synchronizer sleeve (5) from high
speed synchronizer hub gradually with holding down
synchronizer key (3) in order to prevent synchronizer
keys and springs (4) from jumping out.

4) Remove high speed synchronizer hub (1), 3rd gear

synchronizer ring assembly (2), 3rd gear (3), 3rd
gear needle bearing, 3rd gear bush and 2nd gear (4)
from main shaft (5) using special tool, bearing puller
and hydraulic press.

Special tool
(A): 09925–98220

1.89 mm (0.074 in.)

2.07 mm (0.081 in.)

1.98 mm (0.078 in.)

(A)

1

2

3

2

1

I5JB0B520054-02

I5JB0B520055-01

2

1

I5JB0B520056-01

1

3

4

2

5

I5JB0B520057-01

2

1

5

(A)

4

3

I5JB0B520058-01