Suzuki Grand Vitara JB419. Manual — part 112

Manual Transmission/Transaxle: 5B-24

5) Remove 2nd gear needle bearing and 2nd gear

synchronizer ring assembly.

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

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

7) Remove low speed synchronizer hub (1), 1st gear

synchronizer ring assembly (2) and 1st gear (3)
using bearing puller and hydraulic press, and then
1st gear needle bearing.

8) Remove 5th gear, synchronizer ring and needle

bearing.

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

pull out 5th & reverse synchronizer sleeve (3) from
5th & reverse synchronizer hub gradually with
holding down synchronizer key in order to prevent
synchronizer keys and springs from jumped out.

10) Remove reverse gear (1), reverse gear synchronizer

ring and 5th & reverse synchronizer hub (2) using
bearing puller and hydraulic press, and then reverse
gear needle bearing.

Main Shaft Inspection

S5JB0B5206023

• Check clearance “a” between synchronizer outer ring

(1) and gear (2) while lightly pushing synchronizer ring
by hand, and also check chamfered tooth of gear and
synchronizer outer ring. Also, check gear tooth.
Replace with new one if necessary.

Clearance “a” between synchronizer outer ring
and gear (4th, 5th and reverse)
Standard: 1.0 – 1.5 mm (0.040 – 0.059 in.)
Service limit: 0.7 mm (0.028 in.)

3

5

4

2

1

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2

3

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2

3

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1

2

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2

1

2

“a”

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5B-25 Manual Transmission/Transaxle:

• Put synchronizer outer ring (1), inner ring (2) and

center cone (3) together and then measure step
difference “b” between outer ring and inner ring using
straight edge (4). And also check chamfered tooth of
gear and synchronizer ring. Also, check gear tooth.
Replace with new one if necessary.

Difference “b” between synchronizer outer ring
and center cone (1st)
Standard: 0.4 – 0.8 mm (0.016 – 0.031 in.)
Service limit: 0.2 mm (0.008 in.)

• Check clearance “c” between synchronizer outer ring

(1) and center cone (2). If clearance exceeds limit,
replace with new one.

Clearance “c” between synchronizer outer ring
and center cone (1st, 2nd and 3rd)
Standard: 0.41 – 0.7 mm (0.016 – 0.028 in.)
Service limit: 0.3 mm (0.012 in.)

• Check clearance “d” between synchronizer center

cone (1) and gear (2) while lightly pushing
synchronizer outer ring by the hand, and also check
chamfered tooth of gear and synchronizer center
cone. Also, check gear tooth. Replace with new one if
necessary.

Clearance “d” between synchronizer center cone
and gear (2nd and 3rd)
Standard: 0.2 – 0.9 mm (0.008 – 0.035 in.)
Service limit: 0.1 mm (0.004 in.)

• Check clearance “e” between synchronizer inner ring

(1) and gear (2) while lightly pushing synchronizer
inner ring by the hand, and also check chamfered
tooth of gear and synchronizer inner ring. Also, check
gear tooth. Replace with new one if necessary.

Clearance “e” between synchronizer inner ring
and gear (2nd and 3rd)
Standard: 0.7 – 1.5 mm (0.028 – 0.059 in.)
Service limit: 0.3 mm (0.012 in.)

4

4

1

1

3

2

“b”

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2

1

“c”

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2

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“d”

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2

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“e”

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Manual Transmission/Transaxle: 5B-26

• Check clearance “a” between fork (1) and sleeve (2).

Replace those parts if it exceeds limit.

NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Standard: 0.05 – 0.25 mm (0.002 – 0.010 in.)
Service limit: 0.45 mm (0.018 in.)

• Using “V” blocks (1) and dial gauge (2), check runout.

If runout exceeds limit below, replace main shaft (3).

Main shaft runout
Limit: 0.02 mm (0.0008 in.)

• Check chamfered part of each sleeve for damage and

excessive wear, and replace as necessary.

• Check each synchronizer key and synchronizer key

spring 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 Reassembly

S5JB0B5206024

NOTE

• Before installation, wash each part and

apply specified gear oil to sliding faces of
bearing and gear.

• Use new circlips on shaft for installation.

Do not reuse circlips.

1) Clean all components thoroughly, inspect them for

any abnormality and replace with new one as
necessary.

2) Apply oil to reverse gear needle bearing (1), and

then install needle bearing, reverse gear (2) and
reverse gear synchronizer ring (3) to main shaft.

3) Assemble 5th & reverse synchronizer sleeve (4),

synchronizer key (5), synchronizer key spring (6)
and hub (7) as shown in figure.

I5JB0B520068-01

2

3

1

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5B-27 Manual Transmission/Transaxle:

4) Drive in 5th & reverse synchronizer assembly (1)

using bearing puller, special tools and hydraulic
press.

Special tool
(A): 09913–85210
(B): 09945–55410
(C): 09940–54910

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

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

Available circlip thickness

6) Apply oil to 5th gear needle bearing, and then install

needle bearing, 5th gear (1) and 5th gear
synchronizer ring to main shaft.

7) Drive in main shaft bearing (2) using bearing puller,

special tools and hydraulic press.

Special tool
(A): 09913–85210
(B): 09945–55410

8) 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

9) Apply oil to 1st gear needle bearing (1), and then

install needle bearing, 1st gear (2) and 1st gear
synchronizer ring assembly (3) to main shaft.

10) Assemble low speed synchronizer sleeve (4), key

(5), key spring (6) and hub (7) as shown in figure.

1.86 mm (0.073 in.)

2.04 mm (0.080 in.)

1.95 mm (0.077 in.)

(A)

(B)

(C)

1

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(A)

(B)

2

1

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1.77 mm (0.070 in.)

2.04 mm (0.080 in.)

1.86 mm (0.073 in.)

2.13 mm (0.084 in.)

1.95 mm (0.077 in.)

2.22 mm (0.087 in.)

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