Suzuki Grand Vitara JB416 / JB420. Manual - part 255

5B-16 Manual Transmission/Transaxle: 

Remounting
For remounting, reverse dismounting procedure.
• Apply grease to input shaft.

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

• Slant the rear of the engine down, using support 

device (1) and install transmission to engine.

• Use specified torques as given below.

Tightening torque
Transmission to engine bolt and nut (a):  85 N·m (
8.5 kgf-m, 61.5 lb-ft)
Engine rear mounting member bolt (b):  55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Clutch housing lower plate bolt (c):  11 N·m (1.1 
kgf-m, 8.0 lb-ft)
Engine rear mounting No.2 bolt (d):  55 N·m (5.5 
kgf-m, 40.0 lb-ft)

• Set each clamp for wiring and hose securely.
• Install shift control lever referring to “Transmission 

Shift Control Lever Removal and Installation”.

• Connect clutch fluid joint to pipe of clutch operating 

cylinder assembly referring to “Clutch Operating 
Cylinder Assembly Removal and Installation in 
Section 5C”.

• Install exhaust No.2 pipe referring to “Exhaust System 

Components in Section 1K”.

• Fill gear oil to transmission referring to “Manual 

Transmission Oil Change”.

• Fill gear oil to transfer referring to “Transfer Oil 

Change: Motor-Shift Type (Transfer with Shift 
Actuator) in Section 3C” or “Transfer Oil Change: 
Non-Shift Type (Transfer without Shift Actuator) in 
Section 3C”.

• Connect battery and check function of engine, clutch, 

transmission and transfer.

• Install propeller shafts referring to “Propeller Shaft 

Removal and Installation in Section 3D”.

“A”

I5JB0A520031-01

I3JA01520024-01

(a)

(a)

(a)

(c)

(c)

(b)

(b)

(d)

I5JB0A520032-01

Manual Transmission/Transaxle:  5B-17

Manual Transmission Unit Disassembly

S5JB0A5206012

1) Remove clutch operating cylinder assembly from 

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

2) Remove gear shift control lever rear cause assembly 

and gear shift lever front case assembly referring to 
“Gear Shift Control Lever Rear Case Assembly 
Removal and Installation” and “Gear Shift Lever 
Front Case Assembly Removal and Installation”.

3) Separate transfer assembly (1) from transmission 

assembly.

4) Remove adapter case (1) from rear case (2).
5) Remove output shaft assembly (3) from adapter 

case.

6) Remove reverse shaft bolt (1) and back up light 

switch (2).

7) Remove gear shift locating bolts (1), then take out 

locating springs (2) and gear shift shaft balls (3).

8) Remove rear to front case bolts (4), then separate 

rear case from front case tapping front case flange 
with plastic hammer.

9) Remove oil gutter.

10) Remove reverse shaft assembly (1).

11) Remove low gear shift inverse lever (4).

12) Remove low speed gear shift shaft (2) and 5th & 

reverse gear shift fork (3) with 5th speed 
synchronizer sleeve (5).

13) Remove input shaft needle bearing, 5th speed 

synchronizer ring and 5th speed synchronizer levers.

14) Remove input shaft front bearing circlip (1) from 

case using special tool.

Special tool
(A):  09900–06106

1

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1

2

3

1

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2

1

I5JB0A520035-01

1

2

3

4

I5JB0A520036-01

3

5

1

2

4

I5JB0A520037-01

(A)

1

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5B-18 Manual Transmission/Transaxle: 

15) Remove input shaft assembly (1), countershaft 

assembly (2), high speed gear shift fork (3) and low 
speed gear shift fork (4) as assembly from front case 
(5) tapping input shaft end by plastic hammer lightly.

Manual Transmission Unit Reassembly

S5JB0A5206013

1) Assemble input shaft assembly (1), countershaft 

assembly (2), high speed gear shift fork (3) and low 
speed gear shift fork (4), then install them all 
together into front case (5).

CAUTION

!

 

Take care not to damage oil seal lip by input 
shaft, or oil leakage may take place.

 

2) Install input shaft front bearing snap ring (1) using 

special tool.

Special tool
(A):  09900–06106

3) Install low speed gear shift shaft (1) and low gear 

shift inverse lever (2) and tighten with new bolt (3).

Tightening torque
Low gear shift inverse lever bolt (a):  23 N·m (2.3 
kgf-m, 17.0 lb-ft)

4) Fit 5th & reverse gear shift fork (1) to 5th speed 

synchronizer sleeve (2), and install them into input 
shaft and front case in specified direction as shown 
in figure.

5) Set reverse idler gear (1), reverse gear shift lever (2) 

and reverse gear shaft washer (4), insert reverse 
gear shaft (3) into case through idler gear and then 
align hole “B” in shaft with protrusion “A” in case.

1

2

3

5

4

I5JB0A520039-01

1

2

3

5

4

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(A)

1

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A: Chamfered side

1

2

3, (a)

I5JB0A520041-02

1

2

A

I5JB0A520042-01

“B”

1

4

2

3

“A”

I5JB0A520043-01

Manual Transmission/Transaxle:  5B-19

6) Install oil gutter.
7) Install 5th speed synchronizer levers and 5th speed 

synchronizer ring as follows.
a) Fit 5th speed synchronizer levers (1) to hub (2) 

aligning protrusion “A” of 5th speed synchronizer 
levers with groove of hub.

b) Install synchronizer ring (1) to hub (2) in 

specified direction as shown in figure.

8) Install input shaft needle bearing to end of input 

shaft.

9) Clean mating surfaces of both front and rear cases, 

and uniformly apply sealant to front case (1) as 
shown in figure by such amount that its section is 1.2 
mm (0.047 in.) in diameter, and then mate it with rear 
case.

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

10) Install rear case to front case. Tighten case bolts (1) 

to specified torque.

Tightening torque
Transmission case bolt (a):  23 N·m (2.3 kgf-m, 
17.0 lb-ft)

11) Apply thread lock cement to reverse shaft bolt (2), 

and tighten it.

“B”:  Thread lock cement 99000–32110 (Thread 
Lock Cement Super 1322)

Tightening torque
Reverse shaft bolt (b):  23 N·m (2.3 kgf-m, 17.0 
lb-ft)

12) Install back up light switch (3) referring to “Back Up 

Light Switch Removal and Installation”.

13) Apply grease to gear shift shaft balls (1) and locating 

springs (2), then install them.
Apply thread lock cement to gear shift locating bolts 
(3), and then tighten them.

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A) 
“B”:  Thread lock cement 99000–32110 (Thread 
Lock Cement Super 1322)

Tightening torque
Gear shift locating bolt (a):  23 N·m (2.3 kgf-m, 
17.0 lb-ft)

1

2

“A”

“A”

I5JB0A520044-01

1

2

I5JB0A520045-01

1

“A”

“A”

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1, (b)

3

1, (b)

2, “B”, (a)

I5JB0A520047-01

3, “B”, (a)

3, “B”, (a)

2, “A”

2, “A”

1, “A”

1, “A”

I5JB0A520048-01