Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 344

5B-23 Manual Transmission/Transaxle: For Petrol Engine Model

Locating Spring Inspection

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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 Disassembly

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1) Remove snap ring.
2) Remove input shaft front bearing (1) using bearing 

puller and hydraulic press.

3) Remove input shaft union.
4) Hold hatched area (5) of input shaft assembly (1) 

with “V” blocks (4) on vise (2) or the like to stop 
rotation of shaft, undo caulking and input shaft 5th 
hub nut (3).

CAUTION

!

 

Do not hold spline, gear teeth or abrasived 
surface of shaft with vise through “V” blocks 
or the like, otherwise shaft components may 
be damaged.

 

5) Apply bearing puller to 4th gear (1), and drive out 5th 

speed synchronizer hub (2), 3rd gear (3), high speed 
gear needle bearings, 3rd gear bush, high speed 
synchronizer assembly (4) and 4th gear all at once 
from input shaft using metal stick (5) and press.

CAUTION

!

 

To avoid gear teeth from being damaged, 
support 4th gear at flat side of bearing puller.

 

Input Shaft Inspection

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• Check clearance “a” between synchronizer ring (2) 

and gear (1), key slot width “b” in synchronizer ring 
and each chamfered tooth of gear and synchronizer 
ring and replace with new one, if necessary. Also, 
check gear tooth.

Clearance “a” between synchronizer ring and 
gear (Input shaft) (3rd and 4th)
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)

Key slot width “b” (3rd and 4th synchronizer ring)
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)

I5JB0A520051-01

1

2

3

5

4

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2

3

1

5

4

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Manual Transmission/Transaxle: For Petrol Engine Model 5B-24

• Measure width of high speed gear shift fork end “a” 

and groove width of high speed synchronizer sleeve 
“b”, 5th & reverse gear shift fork end “a” and groove 
width of 5th speed synchronizer sleeve “b” and then 
calculate clearance “c” as follows:

If clearance exceeds limit, replace fork bush (1) and 
sleeve.

Clearance “c” between fork and sleeve for high 
speed and 5th speed
Standard: 0.2 – 0.5 mm (0.008 – 0.020 in.)
Limit: 1.0 mm (0.039 in.)

• Check diameter of input shaft (1) and needle bush (2) 

as shown in the figure. If measured value is out of 
specification, replace input shaft and/or bush.

Input shaft and needle bush specifications 
(diameter)

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

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

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

• Using cylinder gauge (1), check inside diameter of 

each gear. If its inside diameter exceeds specification, 
replace it.

Inside diameter (standard) of gear
3rd and 4th gear: 40.000 – 40.025 mm (1.5748 – 
1.5757 in.)

• Check chamfered part of each sleeve for damage and 

excessive wear, and replace as necessary.

• Check each synchronizer key and synchronizer spring 

and replace as necessary.

• Check spline portions and replace parts if excessive 

wear is found.

Clearance “c”

=

“b”

–

“a”

Measuring 

portion

Standard

“a”

30.002 – 30.015 mm

(1.1812 – 1.1816 in.)

“b”

34.975 – 34.991 mm

(1.3770 – 1.3775 in.)

“c”

30.959 – 30.975 mm

(1.2189 – 1.2194 in.)

“d”

27.987 – 28.000 mm

(1.1018 – 1.1023 in.)

“e”

27.967 – 27.980 mm
(1.1011 – 1.1015 in.)

“f”

19.975 – 19.991 mm

(0.7865 – 0.7870 in.)

“g”

28.000 – 28.013 mm

(1.1024 – 1.1028 in.)

“h”

34.975 – 34.991 mm

(1.3770 – 1.3775 in.)

1

“a”

“b”

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“c”

“d”

“e”

“f”

“g” “h”

“b”

“a”

1

2

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2

3

1

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5B-25 Manual Transmission/Transaxle: For Petrol Engine Model

Input 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 snap rings on shaft for 

installation. Don’t reuse snap rings.

 

1) Clean all components thoroughly, inspect them for 

any abnormality and replace with new ones as 
necessary.

2) To ensure lubrication, air blow oil holes (1) and make 

sure that they are free from any obstruction.

3) Drive in input shaft front bearing (1) to input shaft 

using special tool and hammer and then install snap 
ring in specified direction as shown in figure.

Special tool
(A):  09940–51710

NOTE
Input shaft front bearing circlip (2) must be 
installed before input shaft front bearing is 
installed.

 

4) Apply oil to high speed gear needle bearing (5), and 

then install needle bearing, 4th gear (5) and high 
speed synchronizer ring (7) to input shaft.

5) Assemble synchronizer sleeve (4) and hub (3) as 

follows.
a) Fit high speed synchronizer sleeve to hub in 

specified direction as shown in figure.

b) Insert 3 keys (2) to hub.
c) Set springs (1) at specified position as shown in 

figure.

Synchronizer key installation position
: A = B

A: Bearing side

1

1

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(A)

1

2

A

2

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[A]: 4th gear side

C: Key way
D: Projecting end

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Manual Transmission/Transaxle: For Petrol Engine Model 5B-26

6) Drive in high speed synchronizer assembly (1) using 

special tool and hammer.

NOTE

• While press-fitting sleeve & hub, make 

sure that synchronizer ring key slots (2) 
are aligned with keys in sleeve & hub 
assembly.

• Check free rotation of 4th gear after press 

fitting sleeve & hub assembly.

 

Special tool
(A):  09913–84510

7) Check 4th gear (1) thrust clearance by using 

thickness gauge. If clearance is out of specification, 
repress-fit or replace defective part.

4th gear thrust clearance
“a”: 0.10 – 0.30 mm (0.004 – 0.012 in.)

8) Apply oil to high speed gear needle bearing, and 

then install 3rd gear bush (1), high speed gear 
needle bearing (2) and 3rd gear (3).

9) Press-fit 5th speed synchronizer hub (1) using 

special tool and hammer.

Special tool
(A):  09913–84510

10) Check 3rd gear (1) thrust clearance by using 

thickness gauge. If clearance is out of specification, 
repress-fit or replace defective part.

3rd gear thrust clearance
“a”: 0.10 – 0.30 mm (0.004 – 0.012 in.)

(A)

1

2

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“a”

1

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4. 4th gear

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(A)

1

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“a”

1

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