Suzuki Grand Vitara JB416 / JB420. Manual - part 251

5A-138 Automatic Transmission/Transaxle: 

09926–96510

09926–98310

Spring compressor

Clutch spring compressor

)

)

 / ) / ) / ) / ) / )

09926–98320

09926–98390

Spring compressor No. 1 set

Remover

)

 / ) / )

)

 / )

09927–66520

09944–88210

Oil pump remover

Bearing housing installer

)

)

 / )

SUZUKI scan tool
—
This kit includes following 
items. 1. Tech 2, 2. PCMCIA 
card, 3. DLC cable, 4. SAE 
16/19 adapter, 5. Cigarette 
cable, 6. DLC loop back 
adapter, 7. Battery power 
cable, 8. RS232 cable, 9. 
RS232 adapter, 10. RS232 
loop back connector, 11. 
Storage case, 12. ) / )

Manual Transmission/Transaxle:  5B-1

Transmission / Transaxle

Manual Transmission/Transaxle

General Description

Manual Transmission Construction

S5JB0A5201001

The manual transmission consists of the input shaft, output shaft, countershaft and reverse idle gear shaft which are 
installed in the die-cast aluminum alloy case. This transmission provides five forward speeds and one reverse speed.
The 1st, 2nd, 3rd and 4th speeds are for speed reduction drive, 5th speed is for direct drive. The low speed (1st and 
2nd) synchronizer is mounted on the countershaft and engaged with the countershaft 1st or 2nd gear. The high speed 
(3rd and 4th) synchronizer is mounted on of the input shaft and engaged with the input shaft 3rd and 4th gear. The 5th 
speed synchronizer is mounted on the input shaft and engaged with the output shaft. The gear shift lever case is 
located at the upper behind the transmission case and has a cam which prevents direct gear shifting from the 5th 
speed gear into the reverse gear.
As the die-cast aluminum alloy case are sealed with liquid type gasket, it is necessary to use genuine sealant or its 
equivalent on its mating surface when reassembling them. Also, the case fastening bolts must be tightened to 
specified torque by means of the torque wrench and tightening over or below the specified torque should be avoided.
The description under “Repair Instructions” covers the transfer partially which is next to the transmission as well, but 
their gear boxes are independent and each of them has its own drain and filler plugs for the oil change or the level 
check.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

I5JB0A520017-02

1. Input shaft

7. 3rd gear

13. Countershaft

2. Transmission front case

8. Gear shift shaft

14. 2nd gear

3. Reverse idler gear

9. Output shaft gear

15. Transmission rear case

4. Reverse shaft

10. Adapter case

16. Low speed synchronizer hub

5. 4th gear

11. Output shaft

17. 1st gear

6. High speed synchronizer hub

12. 5th speed synchronizer hub

18. Reverse gear

5B-2 Manual Transmission/Transaxle: 

Diagnostic Information and Procedures

Manual Transmission Symptom Diagnosis

S5JB0A5204001

Condition

Possible cause

Correction / Reference Item

Gear slipping out of mesh Worn shift fork shaft

Replace.

Worn shift fork or synchronizer sleeve

Replace.

Weak or damaged locating spring

Replace.

Worn bearings on input shaft, 
countershaft or output shaft

Replace.

Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Missing or disengagement of snap 
ring(s)

Install or replace.

Gears refusing to 
disengage

Weakened or broken synchronizer 
spring

Replace.

Distorted shift shaft or shift fork

Replace.

Hard shifting

Improper clutch pedal free travel

Replace pedal arm and/or clutch master 
cylinder.

Distorted or broken clutch disc

Replace.

Damaged clutch pressure plate

Replace clutch cover.

Air in clutch hydraulic system

Bleed air.

Fluid leakage from clutch fluid line

Locate leaking point and repair.

Worn synchronizer ring

Replace.

Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Distorted shift shaft

Replace.

Noise

Inadequate or insufficient lubricant

Replenish.

Damaged or worn bearing(s)

Replace.

Damaged or worn gear(s)

Replace.

Damaged or worn synchronizer ring

Replace.

Damaged or worn chamfered tooth on 
sleeve or gear

Replace.

Manual Transmission/Transaxle:  5B-3

Repair Instructions

Manual Transmission Assembly Components

S5JB0A5206001

6

9

19

20

21

10

18

5

A

3

8

4

27

OIL

1217G

1217G

2

1

24

1322

23

22

25

26

17

16

15

12

11

28

29

13

14

A

30

31

32

33

7

1217G

OIL

1217G

(a)

(a)

(a)

(a)

(a)

(a)

(a)

34

34

34

35

1217G

37

36

38

1217G

(a)

(a)

(c)

(c)

(c)

(c)

I5JB0A520018-04

1. Transmission front case

: Apply sealant 99000-31260 to mating 
surface of front case and rear case.

15. Low gear shift inverse lever

29. 5th speed synchronizer lever

2. Transmission rear case

: Apply sealant 99000-31260 to mating 
surface of rear case and adapter case.

16. Reverse gear shift lever

30. 5th speed synchronizer sleeve

 3. Adapter case

17. Reverse shift locating

31. 5th speed synchronizer ring

4. Gear shift lever front case assembly

: Apply sealant 99000-31260 to mating 
surface of rear case and gear shift lever 
front case assembly.

18. O-ring

32. Input shaft needle bearing

5. Adapter case oil seal

: Apply grease 99000-25010 to oil seal lip.

19. Back up light switch

33. Output shaft assembly

6. Adapter case bolt

20. Oil filler plug

: Apply sealant 99000-31260 to all around 
thread part of bolt.

34. Transmission to engine bolt