Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 343

5B-19 Manual Transmission/Transaxle: For Petrol Engine Model

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

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

S6JB0A5216020

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

1

2

3

4

I5JB0A520036-01

3

5

1

2

4

I5JB0A520037-01

(A)

1

I5JB0A520038-01

1

2

3

5

4

I5JB0A520039-01

1

2

3

5

4

I5JB0A520039-01

(A)

1

I5JB0A520040-01

Manual Transmission/Transaxle: For Petrol Engine Model 5B-20

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.

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)

A: Chamfered side

1

2

3, (a)

I5JB0A520041-02

1

2

A

I5JB0A520042-01

“B”

1

4

2

3

“A”

I5JB0A520043-01

1

2

“A”

“A”

I5JB0A520044-01

1

2

I5JB0A520045-01

1

“A”

“A”

I5JB0A520046-01

5B-21 Manual Transmission/Transaxle: For Petrol Engine Model

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: For Petrol 
Engine Model”.

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)

14) Install output shaft assembly into rear case.
15) Select a countershaft shim and output shaft shim as 

follows.
a) Measure depth “a” from mating surface of 

adapter case (1) to face processed for 
installation of countershaft rear bearing (2) and 
measure depth “c” from mating surface of 
adapter case to face processed for installation of 
output shaft rear bearing (5) using vernier 
caliper.

b) Measure height “b” from mating surface of rear 

case (3) to countershaft rear bearing (2) and “d” 
from mating surface of rear case (3) to output 
shaft bearing (6) using vernier caliper.

c) Calculate “a” – “b” and “c” – “d”, and select a 

shim according to the following table.

Countershaft shim selection table

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

Clearance “a” – “b”

Thickness of 

countershaft shim

1.15 – 1.24 mm

(0.046 – 0.048 in.)

0.90 mm (0.035 in.)

1.25 – 1.34 mm

(0.050 – 0.052 in.)

1.00 mm (0.039 in.)

1.35 – 1.44 mm

(0.054 – 0.056 in.)

1.10 mm (0.043 in.)

1.45 – 1.54 mm

(0.057 – 0.060 in.)

1.20 mm (0.047 in.)

1.55 – 1.64 mm

(0.061 – 0.064 in.)

1.30 mm (0.051 in.)

1.65 – 1.74 mm

(0.065 – 0.068 in.)

1.40 mm (0.055 in.)

1.75 – 1.84 mm

(0.069 – 0.072 in.)

1.50 mm (0.059 in.)

1.85 – 1.94 mm

(0.073 – 0.076 in.)

1.60 mm (0.063 in.)

1.95 – 2.04 mm

(0.077 – 0.080 in.)

1.70 mm (0.067 in.)

2.05 – 2.14 mm

(0.081 – 0.084 in.)

1.80 mm (0.071 in.)

2.15 – 2.24 mm

(0.085 – 0.088 in.)

1.90 (0.90 + 1.00) mm 

(0.075 (0.035 + 0.039) in.)

Manual Transmission/Transaxle: For Petrol Engine Model 5B-22

Output shaft shim selection table

16) Install selected countershaft shim and output shaft 

shim to adapter case.

17) Clean mating surface of both rear case (1) and 

adapter case, and uniformly apply sealant to rear 
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 adapter case.

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

18) Install rear case to adapter case. Tighten case bolts 

(2) to specified torque.

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

19) Install transfer assembly or extension case assembly 

to transmission assembly. Tighten transfer or 
extension case fastening bolts to specified torque 
referring to “Transfer Assembly Components: Motor-
Shift Type (Transfer with Shift Actuator) in Section 
3C”, “Transfer Assembly Components: Non-Shift 
Type (Transfer without Shift Actuator) in Section 3C” 
or “Extension Case Assembly Components: For 
Petrol Engine Model”.

20) Install gear shift control lever rear case assembly 

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

21) Install clutch operating cylinder assembly to 

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

Clearance “c” – “d”

Thickness of 

countershaft shim

0 – 0.09 mm (0 – 0.04 in.)

—

0.1 – 0.19 mm

(0.004 – 0.007 in.)

0.1 mm (0.004 in.)

0.2 – 0.29 mm

(0.008 – 0.011 in.)

0.2 mm (0.008 in.)

0.3 – 0.39 mm

(0.012 – 0.015 in.)

0.3 mm (0.012 in.)

0.4 – 0.49 mm

(0.016 – 0.019 in.)

0.4 mm (0.016 in.)

0.5 – 0.59 mm

(0.020 – 0.023 in.)

0.5 mm (0.020 in.)

0.6 – 0.69 mm

(0.024 – 0.027 in.)

0.6 mm (0.024 in.)

0.7 – 0.79 mm

(0.028 – 0.031 in.)

0.7 mm (0.028 in.)

“a”

“b”

“d”

2

“c”

5

1

3

4

6

I5JB0A520049-02

2, (a)

2, (a)

2, (a)

2, (a)

“A”

1

I5JB0A520050-01