Suzuki Grand Vitara JB419. Manual - part 109

Manual Transmission/Transaxle:  5B-12

Gear Shift Lever Case Assembly Removal and 
Installation

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Removal

1) Dismount transmission assembly referring to 

“Manual Transmission Assembly Dismounting and 
Remounting”

2) Remove gear shift lever case assembly (1) from 

transmission adapter case.

Installation

NOTE

• Install gear shift lever case to transmission 

adapter case without using sealant for 
functional check.

• Install shift control lever and check to 

make sure that it shifts smoothly 
according to shift pattern as shown in the 
figure.

 

1) Clean mating surface of both adapter case and gear 

shift lever case (2), and uniformly apply sealant to 
lever case as shown in figure by such amount that its 
section is 1.5 mm (0.059 in.) in diameter, and then 
mate it with gear shift lever case.

“A”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)

2) Install lever case to adapter case, and then tighten 

new lever case bolts (1) to specified torque.

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

3) Remount transmission assembly referring to 

“Manual Transmission Assembly Dismounting and 
Remounting”

1

I5JB0B520013-01

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1, (a)

2

“A”

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5B-13 Manual Transmission/Transaxle: 

Gear Shift Lever Case Assembly Disassembly 
and Reassembly

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Disassembly

1) Remove gear shift case plate.
2) Drive out gear shift arm pin and gear shift lever pin 

using special tool, and then disassemble 
components parts.

Special tool
(A):  09922–85811

Reassembly

1) Clean all pants thoroughly, inspect them and replace 

with new one as required.

2) Assemble components parts referring to “Gear Shift 

Lever Case Assembly Components”.

3) Set new gear shift arm inner pin (1) and outer pin (2) 

facing each gap (“a”, “b”) in the opposite direction as 
shown in figure.
Drive gear shift arm pins and gear shift lever pins by 
using special tool.

Special tool
(A):  09922–85811

4) Install gear shift case plate to gear shift lever case 

and tighten them to specified torque.

Tightening torque
Gear shift lever case plate screw:  6 N·m (0.6 kgf-
m, 4.5 lb-ft)

Gear Shift Lever Case Assembly Inspection

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• Check that gear shift shaft moves smoothly without 

abnormal noise. If abnormality is found, replace 
defective part.

• Check bushes and boot for damage and deterioration. 

If abnormality is found, replace defective part.

Engine Rear Mounting Replacement

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When replacement of mounting parts are necessary, 
torque bolts as specified below.

Tightening torque
Engine rear mounting No.1 bolt (a):  55 N·m (5.5 kgf-
m, 40.0 lb-ft)
Engine rear mounting member bolt (b):  55 N·m (5.5 
kgf-m, 40.0 lb-ft)
Engine rear mounting No.2 bolt (c):  55 N·m (5.5 kgf-
m, 40.0 lb-ft)

(A)

(A)

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“a”

“b”

1

2

(A)

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1. Engine rear mounting member

2. Engine rear mounting

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Manual Transmission/Transaxle:  5B-14

Manual Transmission Assembly Dismounting 
and Remounting

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Dismounting

1) Disconnect negative (–) cable of battery.
2) Remove transmission shift control lever referring to 

“Transmission Shift Control Lever Removal and 
Installation”.

3) Remove turbocharger inlet pipe (1), vacuum pump 

(2), engine hanger bracket, throttle body (3), noise 
suppressor wire (5) and air intake pipe (4).

CAUTION

!

 

When removing manual transmission, after 
remove turbocharger inlet pipe, noise 
suppressor wire and vacuum pump.
Otherwise, heater hoses, noise suppressor 
wire and vacuum pump is damaged.

 

4) Detach engine harness clamps and ground wire 

harness from transmission front case.

5) Remove starting motor fastening bolts and 

transmission fastening bolts.

6) Disconnect clutch fluid pipe from joint referring to 

“Clutch Fluid Pipe and Hose Removal and 
Installation in Section 5C in related manual”.

7) Hoist vehicle.
8) Drain oil from transmission and transfer.
9) Remove propeller shafts referring to “Propeller Shaft 

Removal and Installation in Section 3D”.

10) Remove exhaust No. 2 pipe.

11) Remove engine under cover.

12) Disconnect the following couplers and release their 

harness from clamps.
• CKP sensor
• Back up light switch
• Transfer shift actuator
• 4L/N switch
• Center differential lock switch

13) Remove clutch housing plate (1) and harness 

bracket (3).

14) Remove transmission fastening nut and bolts (2).

1

4

2

3

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5

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2

2

2

1

3

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5B-15 Manual Transmission/Transaxle: 

15) Apply transmission jack (1) and remove engine rear 

mounting member (2) taking off its bolts.

16) After removing mounting member, move rearward 

transmission and transfer assemblies placed on jack 
and then lower them.

17) Separate gear shift lever case assembly (2) and 

transfer assembly (3) from transmission assembly 
(1).

Remounting
For remounting, reverse dismounting procedure noting 
the following.
• 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):  55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Engine rear mounting member bolt (b):  55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Clutch housing 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 noise suppressor wire (1) at specified position 

as shown in figure.

2

1

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1

2

3

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“A”

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[A]: Forward

2. Installation position (90

°)

(a)

(b)

(b)

(d)

(a)

(c)

(a)

I5JB0B520021-01

2

[A]

1

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