Suzuki Grand Vitara JB416 / JB420. Manual - part 237

5A-82 Automatic Transmission/Transaxle: 

Manual Selector Assembly Removal and 
Installation

S5JB0A5106044

Removal

1) Disconnect negative cable at battery.
2) Remove front console box.
3) Disconnect shift lever switch connector.
4) Remove manual selector assembly mounting bolts.
5) Disconnect select cable (1) from manual selector 

assembly (2).

Installation
Reverse removal procedure to install manual selector 
assembly noting the following instructions.
• Tighten manual selector assembly mounting bolts to 

specified torque.

Tightening torque
Manual selector assembly mounting bolt:  18 N·m 
(1.8 kgf-m, 13.0 lb-ft)

• Adjust select cable referring to “Select Cable 

Adjustment”

Select Lever Knob Installation

S5JB0A5106045

Screw select lever knob onto select lever by specified 
numbers of rotation below.

Rotation numbers for select lever knob
Installation (a): 13 – 14 rotations

CAUTION

!

 

When installing select lever knob, do not turn 
more than specified numbers of rotation. 
Otherwise select lever knob is damaged.

 

Manual Selector Assembly Inspection

S5JB0A5106046

Check select lever for smooth and clear-cut movement 
individually and position indicator for correct indication.
If a malfunction is found, replace select lever assembly.

“3” Position Switch Inspection

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1) Disconnect negative cable at battery.
2) Remove front console box.
3) Disconnect manual selector connector (1).
4) Measure resistance between “3” position switch 

terminals.

“3” position switch specification
Shift selector lever to “P”, “N” or “D” range: 3.96 
– 4.04 k

Ω

Shift selector lever to “R”, “3”, “2” or “L” range: 
0.99 – 1.01 k

Ω

1

2

I5JB0A510034-02

1,(a)

I4RS0A510058-01

I5JB0A510164-01

Automatic Transmission/Transaxle:  5A-83

Select Cable Component

S5JB0A5106047

Select Cable Adjustment

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1) Loosen manual select cable nut.
2) Shift select lever to “N”.
3) Align center line (1) on manual shift shaft (2) to “N” 

reference line (3) as shown in figure.

4) Tighten manual select cable nut (1) to specified 

torque.

Tightening torque
Manual select cable nut (a):  13 N·m (1.3 kgf-m, 
9.5 lb-ft)

5) After select cable was adjusted, check for the 

following.
• Push vehicle with selector lever shifted to “P”. 

Vehicle should not move.

• Vehicle can not be driven in “N”.
• Vehicle can be driven in “D”, “3”, “2” and “L”.
• Vehicle can be backed in “R”.

1

2

3

4

5

6

7

8

9

(a)

(b)

(c)

(d)

I5JB0A510035-01

1. Manual selector assembly

6. Manual select cable nut

: 13 N

⋅m (1.3 kgf-m, 9.5lb-ft)

2. Manual selector assembly mounting bolt

7. Manual select lever nut

: 12.5 N

⋅m (1.25 kgf-m, 9.0 lb-ft)

3. Select cable

8. Transmission range sensor

: 5.3 N

⋅m (0.53 kgf-m, 4.0 lb-ft)

4. Select cable bracket

9. Transmission range sensor bolt

5. Manual select lever

: 17.5 N

⋅m (1.75 kgf-m, 13.0 lb-ft)

1

2

3

I5JB0A510038-02

1, (a)

I5JB0A510036-02

5A-84 Automatic Transmission/Transaxle: 

Transmission Range Sensor Removal and 
Installation

S5JB0A5106049

Removal

1) Disconnect negative cable at battery.
2) Hoist vehicle.
3) Disconnect transmission range sensor connector 

(1).

4) Disconnect select cable (2) from manual select lever 

(3).

5) Remove manual select lever (3) from transmission 

range sensor (4).

6) Unbend bend parts of lock washer (1), then remove 

manual shift shaft nut (2), lock washer (1) and 
grommet.

7) Remove transmission range sensor (3) by removing 

sensor bolt (4).

Installation

1) Install transmission range sensor (3) and tighten 

sensor bolt (4) temporarily.

2) Install grommet, lock washer (1) and manual shift 

shaft nut (2).
Tighten nut to specified torque. After tightening it, 
bend claws of lock washer (1).

Tightening torque
Manual shift shaft nut (a):  12.5 N·m (1.25 kgf-m, 
9.0 lb-ft)

3) After turning manual shift shaft fully 

counterclockwise, turn it clockwise by 2 notches and 
set it to “N” range.

4) With “N” reference line (5) on range sensor and shaft 

center (6) aligned, tighten transmission range sensor 
bolt (4) to specified torque.

Tightening torque
Transmission range sensor bolt (b):  5.3 N·m (
0.53 kgf-m, 4.0 lb-ft)

5) Install manual select lever (3) to transmission range 

sensor (4).
Tighten nut to specified torque.

Tightening torque
Manual select lever nut (a):  12.5 N·m (1.25 kgf-
m, 9.0 lb-ft)

6) Connect select cable (2) to manual select lever (3).
7) Connect transmission range sensor connector (1).
8) Connect negative cable at battery.
9) Adjust select cable referring to “Select Cable 

Adjustment”

Transmission Range Sensor Inspection and 
Adjustment

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1) Manual select lever to “N” range.
2) Check that center line (2) on manual shift and “N” 

reference line (1) on sensor are aligned. If not, 
loosen sensor bolt (3) and align them.

1

2

3

4

I5JB0A510037-01

4

3

1

2

I4JA01512011-01

6

5

4, (b)

3

1

2, (a)

I4JA01512012-01

2

3

4

(a)

1

I5JB0A510039-02

1

3

2

I5JB0A510040-01

Automatic Transmission/Transaxle:  5A-85

3) Check that engine starts in “N” and “P” ranges but it 

doesn’t start in “D”, “3”, “2”, “L” or “R” range. Also, 
check that back-up lamp lights in “R” range.
If faulty condition cannot be corrected by adjustment, 
disconnect transmission range sensor connector 
and check that continuity exists as shown by moving 
select lever.

Key Interlock Cable Removal and Installation

S5JB0A5106051

NOTE
Do not bend interlock cable excessively 
when removing and installing it, or system 
will not operate correctly.

 

Removal

1) Disconnect negative (–) cable from battery.
2) If equipped with air bag system, disable air bag 

system. Refer to “Disabling Air Bag System in 
Section 8B”.

3) Remove steering column hole cover.
4) Tilt steering column if steering column is adjustable. 

If no adjustable, loosen steering column bolts.

5) Remove steering column cover.
6) Turn ignition switch to ACC position.

7) Pull out key interlock cable (1) from key cylinder 

cover (2) while pressing checkhook with slotted 
screwdriver or the like.

8) Turn ignition switch to LOCK position.
9) Remove front console box.

10) Detach cable end (1) from interlock cam (2) while 

pressing claws (3) of interlock cam boss.
At this time, be careful not to cause damage to its 
claws.
Detach cable casing cap (4) from selector bracket 
(5) while pressing checkhook.

11) Remove interlock cable.

Installation

1) Lay interlock cable to its original cabling route.
2) Turn ignition switch to “ACC” position.
3) Insert cable casing cap (1) into key cylinder cover (2) 

securely.

[A]: Sensor position
[B]: Terminal No.

1

2

3

4

5

6

7

8

9

P

R

N

D 

and 

3

2

L

1

2

3

4

5

6

7

8

9

[B]

[A]

I5JB0A510041-02

2

1

I5JB0A510062-01

4

5

3

2

1

I5JB0A510063-01

2

1

I5JB0A510064-01