Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 345

5B-27 Manual Transmission/Transaxle: For Petrol Engine Model

11) Tighten input shaft 5th hub nut to specified torque in 

the same manner as step 4) of “Input Shaft 
Disassembly: For Petrol Engine Model”.

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.

 

Tightening torque
Input shaft 5th hub nut:  210 N·m (21.0 kgf-m, 
152.0 lb-ft)

12) Caulk input shaft 5th hub nut (2) using caulking tool.
13) Drive in new input shaft union (1) using puller and 

hydraulic press.

Countershaft Disassembly and Assembly

S6JB0A5216025

Disassembly

1) Remove countershaft rear bearing (1) using bearing 

puller, metal stick (2) and hydraulic press.

2) Hold hatched area (5) of countershaft assembly (1) 

with “V” blocks (4) on vise (2) or the like to stop 
rotation of shaft, undo caulking and countershaft 
front bearing nut (3).

CAUTION

!

 

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

 

3) Apply bearing puller to 2nd gear (1), and drive out 

countershaft front bearing (2), countershaft reverse 
gear (3), 1st gear (4), countershaft gear needle 
bearings, countershaft low needle bearing bush, low 
speed synchronizer assembly (5) and 2nd gear all at 
once from countershaft using metal stick (6) and 
hydraulic press.

CAUTION

!

 

To avoid gear teeth from being damaged, 
support 2nd gear at flat side of bearing puller.

 

1

2

I5JB0A520066-01

1

2

I5JB0A520067-01

5

1

2

3

4

I5JB0A520068-01

2

1

6

3

4

5

I5JB0A520069-01

Manual Transmission/Transaxle: For Petrol Engine Model 5B-28

Assembly

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 countershaft rear bearing (1) using special 

tool and hammer.

Special tool
(A):  09913–84510

4) Apply oil to countershaft gear needle bearing (6), 

and then install needle bearing, 2nd gear (5) and low 
speed synchronizer ring (7).

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

follows.
a) Fit low 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

6) Drive in low 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 2nd gear after press-

fitting sleeve & hub assembly.

 

Special tool
(A):  09913–84510

1

I5JB0A520070-01

1

(A)

I5JB0A520071-01

[A]: 1st gear side

C: Key way
D: Chamfered side

I5JB0A520072-01

1

2

(A)

I5JB0A520073-01

5B-29 Manual Transmission/Transaxle: For Petrol Engine Model

7) Check 2nd gear (1) thrust clearance by using 

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

2nd gear thrust clearance
“a”: 0.10 – 0.30 mm (0.004 – 0.012 in.)

8) Apply oil to countershaft gear needle bearing, and 

then countershaft low needle bush, needle bearing 
and 1st gear (1) to countershaft.

9) Press-fit countershaft reverse gear (2) using special 

tool and hammer.

Special tool
(A):  09913–80113

10) Press-fit countershaft front bearing (1) using special 

tool and hammer.

Special tool
(A):  09913–84510

11) Check low gear (1) thrust clearance by using 

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

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

12) Tighten countershaft front bearing nut to specified 

torque while locking counter shaft in the same 
manner as step 2) of “Disassembly” under 
“Countershaft Disassembly and Assembly: For 
Petrol Engine Model”.

CAUTION

!

 

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

 

Tightening torque
Countershaft front bearing nut:  210 N·m (21.0 
kgf-m, 152.0 lb-ft)

13) Caulk countershaft front bearing nut using caulking 

tool and hammer.

1

“a”

I5JB0A520074-01

1

(A)

2

I5JB0A520075-01

1

(A)

I5JB0A520076-01

“a”

1

I5JB0A520077-01

Manual Transmission/Transaxle: For Petrol Engine Model 5B-30

Countershaft and Reverse Idle Gear Inspection

S6JB0A5216026

• Using micrometer, check diameter of countershaft (1) 

and needle bush (2) as shown. If measured value is 
out of specification, replace counter and/or bush.

Countershaft diameter (standard)

• Measure width “a” of low speed gear shift fork and 

groove width “b” of low speed gear synchronizer 
sleeve and then calculate clearance “c” as follows:

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

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

• 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 (Countershaft) (1st and 2nd)
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)

Key slot width “b” (1st and 2nd synchronizer ring)
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)

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

countershaft 1st and 2nd gears (2). If measured value 
exceeds specification, replace countershaft 5th gear.

Countershaft 1st and 2nd gears diameter
Standard: 40.000 – 40.025 mm (1.5748 – 1.5757 in.)

Measuring 

portion

Standard

“a”

25.002 – 25.015 mm

(0.9843 – 0.9848 in.)

“b”

27.987 – 28.000 mm

(1.1019 – 1.1023 in.)

“c”

27.987 – 28.000 mm

(1.1019 – 1.1023 in.)

“d”

30.959 – 30.975 mm

(1.2189 – 1.2194 in.)

“e”

34.975 – 34.991 mm

(1.3770 – 1.3775 in.)

“f”

25.002 – 25.015 mm

(0.9843 – 0.9848 in.)

“g”

28.000 – 28.013 mm

(1.1023 – 1.1028 in.)

“h”

34.975 – 34.991 mm

(1.3770 – 1.3776 in.)

Clearance “c”

=

“b”

–

“a”

“c”

“d”

“e”

“f”

“g”

“h”

“b”

“a”

1

2

I6JB01520015-01

1

“a”

“b”

I5JB0A520055-01

I5JB0A520079-01

IYSQ01522122-01