Suzuki Grand Vitara JB419. Manual - part 112

Manual Transmission/Transaxle:  5B-24

5) Remove 2nd gear needle bearing and 2nd gear 

synchronizer ring assembly.

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

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

7) Remove low speed synchronizer hub (1), 1st gear 

synchronizer ring assembly (2) and 1st gear (3) 
using bearing puller and hydraulic press, and then 
1st gear needle bearing.

8) Remove 5th gear, synchronizer ring and needle 

bearing.

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

pull out 5th & reverse synchronizer sleeve (3) from 
5th & reverse synchronizer hub gradually with 
holding down synchronizer key in order to prevent 
synchronizer keys and springs from jumped out.

10) Remove reverse gear (1), reverse gear synchronizer 

ring and 5th & reverse synchronizer hub (2) using 
bearing puller and hydraulic press, and then reverse 
gear needle bearing.

Main Shaft Inspection

S5JB0B5206023

• Check clearance “a” between synchronizer outer ring 

(1) and gear (2) while lightly pushing synchronizer ring 
by hand, and also check chamfered tooth of gear and 
synchronizer outer ring. Also, check gear tooth. 
Replace with new one if necessary.

Clearance “a” between synchronizer outer ring 
and gear (4th, 5th and reverse)
Standard: 1.0 – 1.5 mm (0.040 – 0.059 in.)
Service limit: 0.7 mm (0.028 in.)

3

5

4

2

1

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1

2

3

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1

2

3

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1

2

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1

2

1

2

“a”

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5B-25 Manual Transmission/Transaxle: 

• Put synchronizer outer ring (1), inner ring (2) and 

center cone (3) together and then measure step 
difference “b” between outer ring and inner ring using 
straight edge (4). And also check chamfered tooth of 
gear and synchronizer ring. Also, check gear tooth. 
Replace with new one if necessary.

Difference “b” between synchronizer outer ring 
and center cone (1st)
Standard: 0.4 – 0.8 mm (0.016 – 0.031 in.)
Service limit: 0.2 mm (0.008 in.)

• Check clearance “c” between synchronizer outer ring 

(1) and center cone (2). If clearance exceeds limit, 
replace with new one.

Clearance “c” between synchronizer outer ring 
and center cone (1st, 2nd and 3rd)
Standard: 0.41 – 0.7 mm (0.016 – 0.028 in.)
Service limit: 0.3 mm (0.012 in.)

• Check clearance “d” between synchronizer center 

cone (1) and gear (2) while lightly pushing 
synchronizer outer ring by the hand, and also check 
chamfered tooth of gear and synchronizer center 
cone. Also, check gear tooth. Replace with new one if 
necessary.

Clearance “d” between synchronizer center cone 
and gear (2nd and 3rd)
Standard: 0.2 – 0.9 mm (0.008 – 0.035 in.)
Service limit: 0.1 mm (0.004 in.)

• Check clearance “e” between synchronizer inner ring 

(1) and gear (2) while lightly pushing synchronizer 
inner ring by the hand, and also check chamfered 
tooth of gear and synchronizer inner ring. Also, check 
gear tooth. Replace with new one if necessary.

Clearance “e” between synchronizer inner ring 
and gear (2nd and 3rd)
Standard: 0.7 – 1.5 mm (0.028 – 0.059 in.)
Service limit: 0.3 mm (0.012 in.)

4

4

1

1

3

2

“b”

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1

2

1

“c”

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2

2

1

“d”

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1

2

2

1

“e”

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Manual Transmission/Transaxle:  5B-26

• Check clearance “a” between fork (1) and sleeve (2). 

Replace those parts if it exceeds limit.

NOTE
For correct judgement of parts replacement, 
carefully inspect contact portion of fork and 
sleeve.

 

Clearance “a” between fork and sleeve
Standard: 0.05 – 0.25 mm (0.002 – 0.010 in.)
Service limit: 0.45 mm (0.018 in.)

• Using “V” blocks (1) and dial gauge (2), check runout. 

If runout exceeds limit below, replace main shaft (3).

Main shaft runout
Limit: 0.02 mm (0.0008 in.)

• Check chamfered part of each sleeve for damage and 

excessive wear, and replace as necessary.

• Check each synchronizer key and synchronizer key 

spring 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 Reassembly

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NOTE

• Before installation, wash each part and 

apply specified gear oil to sliding faces of 
bearing and gear.

• Use new circlips on shaft for installation. 

Do not reuse circlips.

 

1) Clean all components thoroughly, inspect them for 

any abnormality and replace with new one as 
necessary.

2) Apply oil to reverse gear needle bearing (1), and 

then install needle bearing, reverse gear (2) and 
reverse gear synchronizer ring (3) to main shaft.

3) Assemble 5th & reverse synchronizer sleeve (4), 

synchronizer key (5), synchronizer key spring (6) 
and hub (7) as shown in figure.

I5JB0B520068-01

2

3

1

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5B-27 Manual Transmission/Transaxle: 

4) Drive in 5th & reverse synchronizer assembly (1) 

using bearing puller, special tools and hydraulic 
press.

Special tool
(A):  09913–85210
(B):  09945–55410
(C):  09940–54910

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

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

Available circlip thickness

6) Apply oil to 5th gear needle bearing, and then install 

needle bearing, 5th gear (1) and 5th gear 
synchronizer ring to main shaft.

7) Drive in main shaft bearing (2) using bearing puller, 

special tools and hydraulic press.

Special tool
(A):  09913–85210
(B):  09945–55410

8) 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

9) Apply oil to 1st gear needle bearing (1), and then 

install needle bearing, 1st gear (2) and 1st gear 
synchronizer ring assembly (3) to main shaft.

10) Assemble low speed synchronizer sleeve (4), key 

(5), key spring (6) and hub (7) as shown in figure.

1.86 mm (0.073 in.)

2.04 mm (0.080 in.)

1.95 mm (0.077 in.)

(A)

(B)

(C)

1

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(A)

(B)

2

1

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1.77 mm (0.070 in.)

2.04 mm (0.080 in.)

1.86 mm (0.073 in.)

2.13 mm (0.084 in.)

1.95 mm (0.077 in.)

2.22 mm (0.087 in.)

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