Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 341

5B-11 Manual Transmission/Transaxle: For Petrol Engine Model

Transmission Shift Control Lever Removal and 
Installation

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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):  10 N·m (1.0 kgf-
m, 7.5 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

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• Check transmission shift control lever lower portion 

and control lever locating sheet for excessive wear.

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

6

4

5

3

1

2

I5JB0A520023-02

“A”

1, (a), “B”

I5JB0A520024-03

3

(a)

1

2

I5JB0A520025-02

2

(a)

1

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Manual Transmission/Transaxle: For Petrol Engine Model 5B-12

Back Up Light Switch Removal and Installation

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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 (2) to transmission rear case.

Tightening torque
Back up light switch (a):  19 N·m (1.9 kgf-m, 14.0 
lb-ft)

• Check back up light for proper function with ignition 

switch turned ON and reverse position.

Back Up Light Switch Inspection

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

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

Gear Shift Control Lever Rear Case Assembly 
Removal and Installation

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4WD model
Removal

1) Dismount transmission assembly from vehicle 

referring to “Manual Transmission Assembly 
Dismounting and Remounting: For Petrol Engine 
Model”.

2) Remove gear shift control lever rear case assembly 

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

1

I5JB0A520005-01

1

2, (a)

I5JB0A520004-01

I5JB0A520006-01

1

2

I5JB0A520007-03

5B-13 Manual Transmission/Transaxle: For Petrol Engine Model

Installation

1) Install gear shift control lever rear case assembly 

with its plate to transfer case referring to figure for 
proper installing direction of control shaft joint bolt 
(2). Tighten plate bolts (1) and control shaft joint nut 
(3) to specified torque.

Tightening torque
Plate bolt (a):  23 N·m (2.3 kgf-m, 17.0 lb-ft)
Control shaft joint nut (b):  18 N·m (1.8 kgf-m, 
13.0 lb-ft)

2) Remount transmission assembly to vehicle referring 

to “Manual Transmission Assembly Dismounting and 
Remounting: For Petrol Engine Model”.

2WD model
Removal

1) Dismount transmission assembly from vehicle 

referring to “Manual Transmission Assembly 
Dismounting and Remounting: For Petrol Engine 
Model”.

2) Remove gear shift control lever rear case assembly 

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

Installation

1) Install gear shift control rear case assembly with its 

plate to extension case referring to figure for proper 
installing direction of control shaft joint bolt (2). 
Tighten shift lever bolt (4) and then plate bolts (1) 
and control shaft joint nut (3) to specified torque.

Tightening torque
Plate bolt (a):  23 N·m (2.3 kgf-m, 17.0 lb-ft)
Control shaft joint nut (b):  18 N·m (1.8 kgf-m, 
13.0 lb-ft)
Shift lever bolt (c):  23 N·m (2.3 kgf-m, 17.0 lb-ft)

2) Remount transmission assembly to vehicle referring 

to “Manual Transmission Assembly Dismounting and 
Remounting: For Petrol Engine Model”.

Gear Shift Control Lever Rear Case Assembly 
Disassembly and Reassembly

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Disassembly and reassembly component parts referring 
to “Gear Shift Control Lever Rear Case Assembly 
Components: For Petrol Engine Model”.

Gear Shift Control Lever Rear Case Assembly 
Inspection

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• Check that gear shift control shaft moves smoothly 

without abnormal noise. If abnormality is found, 
replace defective part.

• Check bush and boot for damage and deterioration. If 

abnormality is found, replace defective part.

1, (a)

2

3, (b)

I5JB0A520008-03

1

2

I6JB0A521003-01

1, (a)

2

3, (b)

4, (c)

I6JB0A521004-01

Manual Transmission/Transaxle: For Petrol Engine Model 5B-14

Gear Shift Lever Front Case Assembly Removal 
and Installation

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Removal

1) Dismount transmission assembly referring to 

“Manual Transmission Assembly Dismounting and 
Remounting: For Petrol Engine Model”.

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

from transmission rear case.

Installation

NOTE

• Install gear shift lever front case to 

transmission rear 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 rear case and gear 

shift lever front case (2), and uniformly apply sealant 
to lever case as shown in figure by such amount that 
its section is 1.2 mm (0.047 in.) in diameter, and then 
mate it with gear shift lever front case.

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

2) Install lever case to rear 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) Connect gear shift shaft (3) of lever case assembly 

to gear shift control shaft (4) of gear shift control 
lever rear case assembly referring to figure for 
proper installing direction of control shaft joint bolt 
(5). Tighten control shaft joint nut (6) to specified 
torque.

Tightening torque
Control shaft joint nut (b):  18 N·m (1.8 kgf-m, 
13.0 lb-ft)

4) Remount transmission assembly referring to 

“Manual Transmission Assembly Dismounting and 
Remounting: For Petrol Engine Model”.

1

I5JB0A520009-03

I5JB0A520010-01

1, (a)

3

5

4

6, (b)

2

“A”

2

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