Suzuki Grand Vitara JB419. Manual - part 111

Manual Transmission/Transaxle:  5B-20

12) Set new gear shift shaft inner pin (1) and outer pin 

(2) facing each gap (“a”, “b”) in the opposite direction 
as shown in figure. Drive each gear shift shaft pin by 
using special tool.

Special tool
(A):  09922–85811

13) Clean mating surfaces of both front case (1) and rear 

case (2), and uniformly apply sealant to front 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 rear 
case.

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

14) Install front case to rear case. Tighten front case 

bolts (3) to specified torque.

Tightening torque
Front case bolt (a):  45 N·m (4.5 kgf-m, 32.5 lb-ft)

15) Apply grease to gear shift locating balls (1) and 

springs (2), then install them. Apply sealant to gear 
shift locating bolts (3), and then tighten bolts to 
specified torque.

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A)
“B”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)

Tightening torque
Gear shift locating bolt (a):  19 N·m (1.9 kgf-m, 
14.0 lb-ft)

16) Install new circlip (1) of main shaft rear bearing to 

rear case using snap ring pliers (2).

17) Install reverse shift shaft (1), rear bearing plate (2) 

and oil gutter (3) as shown in figure. Tighten rear 
bearing plate bolts (4) to specified torque.

Tightening torque
Rear bearing plate bolt (a):  22 N·m (2.2 kgf-m, 
16.0 lb-ft)

“a”

“b”

1

2

(A)

I5JB0B520042-01

1

2

3, (a)

1

3, (a)

3, (a)

3, (a)

1

“A”

I5JB0B520043-02

2, “A”

3, “B”, (a)

2, “A”

1,“A”

1, “A”

I5JB0B520044-01

2

1

I5JB0B520045-01

1

2

1

3

4, (a)

4, (a)

2

I5JB0B520046-01

5B-21 Manual Transmission/Transaxle: 

18) Install reverse shift limit spring (1) and cam (2) to 

reverse shift shaft (3), and then hook spring to rear 
bearing plate.

19) Set new gear shift shaft inner pin (4) and outer pin 

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

Special tool
:  09922–85811

20) Install gear shift & select lever assembly (1) and 

each gear shift yoke (2).

21) Set new gear shift yoke inner pin (3) and outer pin 

(4) facing each gap (“a”, “b”) in the opposite direction 
as shown in figure. Drive gear shift yoke pin by using 
special tool.

Special tool
(A):  09922–85811

22) Clean mating surfaces of both rear case (1) and 

adapter case (2), and uniformly apply sealant to rear 
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 adapter case.

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

23) Install rear case to adapter case. Tighten adapter 

case No.1 bolts (3) and new adapter case No.2 bolt 
(4) to specified torque.

Tightening torque
Adapter case No.1 bolt (a):  45 N·m (4.5 kgf-m, 
32.5 lb-ft)
Adapter case No.2 bolt (b):  54 N·m (5.4 kgf-m, 
39.0 lb-ft)

A: Upper side

“a”

“b”

4

5 

A

2

3

2

1

3

I5JB0B520047-04

“a”

“b”

3

4 

(A)

2

1

I5JB0B520048-02

1

2

3, (a)

4, (b)

3, (a)

1

2

“A”

I5JB0B520049-02

Manual Transmission/Transaxle:  5B-22

24) Clean mating surfaces of both reverse idle gear case 

(1) and rear case (2), and uniformly apply sealant to 
reverse idle gear 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 rear case.

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

25) Install reverse idle gear case to rear case with new 

bolts. Tighten No.1 bolts (3) and No.2 bolts (4) to 
specified torque.

Tightening torque
Reverse idle gear case No.1 bolt and No.2 bolt 
(a):  26 N·m (2.6 kgf-m, 19.0 lb-ft)

26) Apply grease to select guide pins (1), and then install 

select guide pins, select return low speed spring 
(short) (2) and select return 5th & reverse spring 
(long) (3). Apply sealant to select return bolts, and 
then tighten bolts (4) to specified torque.

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A)
“B”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)

Tightening torque
Select return bolt (a):  25 N·m (2.5 kgf-m, 18.0 lb-
ft)

27) Install buck up light switch (1), new washer and pin 

to front case (2) referring to “Back Up Light Switch 
Removal and Installation”.

28) Install clutch operating cylinder assembly to 

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

Locating Spring Inspection

S5JB0B5206021

Check locating springs for deterioration and replace with 
new ones if necessary.

Locating spring free length
Standard: 44.6 mm (1.756 in.)
Service limit: 40.1 mm (1.579 in.)

Input Shaft Assembly Disassembly and 
Reassembly

S5JB0B5206031

Disassembly

1) Remove input shaft circlip from input shaft using 

snap ring pliers.

2) Remove input shaft bearing (1) from input shaft (2) 

using bearing puller and hydraulic press.

3, (a)

2

1

4, (a)

3, (a)

1

“A”

I5JB0B520050-01

4, “B”, (a)

4, “B”, (a)

1, “A”

2

3

1, “A”

I5JB0B520051-01

1

2

I5JB0B520052-01

2

1

I5JB0B520053-01

5B-23 Manual Transmission/Transaxle: 

Reassembly

1) Clean all components thoroughly, inspect them for 

any abnormality and replace with new ones as 
necessary.

2) Drive in input shaft bearing (1) onto input shaft facing 

groove (2) side to downward in figure (3) using 
special tool and hydraulic press.

Special tool
(A):  09913–75520

3) Select circlip (1) that will make thrust clearance “a” of 

bearing 0.15 mm (0.006 in) or less and install it.

Available circlip thickness

Input Shaft Inspection

S5JB0B5206032

• Check chamfered teeth of gear for damage and 

excessive wear, and replace as necessary.

• Check spline portions and replace parts if excessive 

wear is found.

• Check bearing for smooth rotation and replace it if 

abnormality is found.

Main Shaft Disassembly

S5JB0B5206022

1) Remove main shaft bearing circlip using snap ring 

pliers.

2) Remove main shaft bearing (1) from main shaft (2) 

using bearing puller and hydraulic press.

3) Remove circlip (1) using snap ring pliers (2) and then 

pull out high speed synchronizer sleeve (5) from high 
speed synchronizer hub gradually with holding down 
synchronizer key (3) in order to prevent synchronizer 
keys and springs (4) from jumping out.

4) Remove high speed synchronizer hub (1), 3rd gear 

synchronizer ring assembly (2), 3rd gear (3), 3rd 
gear needle bearing, 3rd gear bush and 2nd gear (4) 
from main shaft (5) using special tool, bearing puller 
and hydraulic press.

Special tool
(A):  09925–98220

1.89 mm (0.074 in.)

2.07 mm (0.081 in.)

1.98 mm (0.078 in.)

(A)

1

2

3

2

1

I5JB0B520054-02

I5JB0B520055-01

2

1

I5JB0B520056-01

1

3

4

2

5

I5JB0B520057-01

2

1

5

(A)

4

3

I5JB0B520058-01