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Suzuki Grand Vitara JB416 / JB420. Manual - part 253

5B-8 Manual Transmission/Transaxle:

Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components

S5JB0A5206003

[A]

[B]

[C]

OIL

(a)

I5JB0A520003-01

[A]: Input shaft assembly

14. 5th speed synchronizer hub

30. Low speed synchronizer spring

[B]: Output shaft assembly

15. High speed gear needle bearing

31. Low speed synchronizer key

[C]: Countershaft assembly

16. Input shaft 3rd gear bush

32. Low speed synchronizer hub

1. Snap ring

17. Input shaft 5th hub nut

33. Low speed synchronizer sleeve

2. Input shaft front bearing

18. Output shaft

34. Countershaft gear needle bearing

3. Input shaft front bearing circlip

19. Output shaft front bearing

35. 2nd gear

4. Input shaft

20. Output shaft gear

36. Countershaft

5. Input shaft union

21. Output shaft rear bearing

37. Countershaft rear bearing

Manual Transmission/Transaxle: 5B-9

Manual Transmission Oil Change

S5JB0A5206004

1) Before changing or inspecting oil, be sure to stop

engine and lift vehicle horizontally.

2) With vehicle lifted up, check oil level and leakage. If

leakage exists, correct or repair it.

NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten

it to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Transmission oil drain plug (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)

NOTE
If water or rust is mixed in drained oil, be
sure to check breather hose and boot of
transmission.

6) Pour new specified oil until oil level reaches bottom

of oil filler plug hole (3) as shown in figure.

NOTE
It is highly recommended to use API 75 W-90
gear oil.

Gear oil specifications
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)

Manual transmission gear oil capacity
Reference: 1.9 liters (4.0 / 3.3 US / Imp. pt)

7) Apply sealant to thread of filler plug, and then tighten

it to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Oil filler plug (b): 23 N·m (2.3 kgf-m, 17.0 lb-ft)

6. High speed gear needle bearing

22. Output shaft rear snap ring

38. 5th speed synchronizer sleeve

7. 4th gear

23. Countershaft front bearing nut

39. 5th speed synchronizer lever

8. High speed synchronizer ring

24. Countershaft front bearing

40. 5th speed synchronizer ring

9. High speed synchronizer spring

25. Countershaft reverse gear

: 210 N

⋅m (21.0 kgf-m, 152.0 lb-ft)

10. High speed synchronizer sleeve

26. Countershaft low needle bush

: Do not reuse.

11. High speed synchronizer key

27. Countershaft gear needle bearing

: Apply transmission oil.

12. High speed synchronizer hub

28. 1st gear

13. 3rd gear

29. Low speed synchronizer ring

2, (b), “A”

1, (a), “A”

I5JB0A520020-01

I5JB0A520022-02

80W-90

Temperature

-30

-20

-10

-22

-4

104

75W-85, 75W-90

[A]

I5JB0A520021-02

5B-10 Manual Transmission/Transaxle:

Transmission Shift Control Lever Removal and
Installation

S5JB0A5206005

Removal

1) Remove front console box referring to “Console Box

Components in Section 9H”.

2) Lift up boot cover (1), boot (2) and sheet (3).
3) Remove case cover (4) and take out shift control

lever (5) from gear shift lever rear case (6).

Installation

1) Tighten new control lever locating bolts (1) to

specified torque, if removed.

Tightening torque
Control lever locating bolt (a): 9 N·m (0.9 kgf-m,
6.5 lb-ft)

2) Apply grease to pivot portions and seat, then install

shift control lever.

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

3) Set shift control lever (2) to gear shift lever rear case.
4) Install case cover (1) to gear shift lever rear case (3).

Tighten case cover bolt to specified torque.

Tightening torque
Case cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)

5) Install sheet, boot (1) with boot cover (2) to floor

panel.

Tightening torque
Control lever boot cover bolt (a): 12 N·m (1.2
kgf-m, 9.0 lb-ft)

6) Install front console box referring to “Console Box

Components in Section 9H”.

Transmission Shift Control Lever Inspection

S5JB0A5206006

• Check transmission shift control lever lower portion

and control lever locating sheet for excessive wear.

• Check boot for damage.
Correct or replace if necessary.

I5JB0A520023-02

“A”

1, (a), “B”

I5JB0A520024-03

(a)

I5JB0A520025-02

(a)

I5JB0A520027-02

Manual Transmission/Transaxle: 5B-11

Back Up Light Switch Removal and Installation

S5JB0A5206007

Removal

WARNING

Refrain from work while exhaust No.2 pipe is
hot.

NOTE

• When replacing switch, use care not to let

dust enter transmission through switch
hole.

1) Hoist vehicle and disconnect connector from back up

light switch.

2) Remove back up light switch (1) from transmission

rear case.

Installation
Reverse removal procedure for installation noting the
following.
• Apply oil to new O-ring (1) and then install back up

light switch to transmission rear case.

Tightening torque
Back up light switch (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)

• Check back up light for proper function with ignition

switch turned ON and reverse position.

Back Up Light Switch Inspection

S5JB0A5206008

Check back up light switch for function using ohmmeter.
If resistance is not as specified below, replace back up
light switch.

Back up lamp switch specification
Switch ON (Push): Continuity
Switch OFF (Release): No continuity

Gear Shift Control Lever Rear Case Assembly
Removal and Installation

S5JB0A5206028

Removal

1) Dismount transmission assembly from vehicle

referring to “Manual Transmission Assembly
Dismounting and Remounting”

2) Remove gear shift control lever rear case assembly

(1) with plate (2) from transfer case.

I5JB0A520005-01

2, (a)

I5JB0A520004-01

I5JB0A520006-01

I5JB0A520007-03

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