Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 348

5B-39 Manual Transmission/Transaxle: For Diesel Engine Model

For Diesel Engine Model

General Description

Manual Transmission Construction

S6JB0A5221001

The manual transmission consists of the input shaft, main shaft, countershaft and reverse idle gear shaft which are 
installed in the die-cast aluminum alloy case. This transmission provides five forward speeds and one reverse speed.
The 1st, 2nd and 3rd speeds are for speed reduction drive, 4th speed is for direct drive 5th speed is for speed 
increasing drive. The low speed (1st and 2nd) synchronizer is mounted on the main shaft and engaged with the main 
shaft 1st or 2nd gear. The high speed (3rd and 4th) synchronizer is mounted on of the main shaft and engaged with 
the main shaft 3rd gear or input shaft 4th gear. The 5th & reverse synchronizer is mounted on the main shaft and 
engaged with the main shaft 5th or reverse gear. The gear shift lever case is located at the upper behind the 
transmission case and has a cam which prevents direct gear shifting from the 5th speed gear into the reverse gear.
The double cone synchronizing mechanism is provided to 1st gear synchromesh. The triple cone synchronizing 
mechanism is provided to 2nd and 3rd gear synchromesh.
As the die-cast aluminum alloy case are sealed with liquid type gasket, it is necessary to use genuine sealant or its 
equivalent on its mating surface when reassembling them. Also, the case fastening bolts must be tightened to 
specified torque by means of the torque wrench and tightening over or below the specified torque should be avoided.
The description under “Repair Instructions” covers the transfer partially which is next to the transmission as well, but 
their gear boxes are independent and each of them has its own drain and filler plugs for the oil change or the level 
check.

I5JB0B520001-01

1. Input shaft 

6. 3rd gear

11. 5th & reverse synchronizer hub

16. Rear case

2. Transmission front case

7. 2nd gear

12. Main shaft

17. Reverse idle gear

3. Input shaft bearing retainer 

8. Low speed synchronizer hub

13. Reverse shift shaft

18. Reverse idle gear shaft

4. 4th gear

9. 1st gear

14. Adapter case

19. Reverse idle gear case

5. High speed synchronizer hub

10. Reverse gear

15. Countershaft

Manual Transmission/Transaxle: For Diesel Engine Model 5B-40

Diagnostic Information and Procedures

Manual Transmission Symptom Diagnosis

S6JB0A5224001

Condition

Possible cause

Correction / Reference Item

Gear slipping out of mesh Worn shift fork shaft

Replace.

Worn shift fork or synchronizer sleeve

Replace.

Weak or damaged locating spring

Replace.

Worn bearings on input shaft, 
countershaft or main shaft

Replace.

Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Missing or disengagement of snap 
ring(s)

Install or replace.

Gears refusing to 
disengage

Weakened or broken synchronizer key 
spring

Replace.

Distorted shift shaft or shift fork

Replace.

Hard shifting

Improper clutch pedal free travel

Replace pedal arm and/or clutch master 
cylinder.

Distorted or broken clutch disc

Replace.

Damaged clutch pressure plate

Replace clutch cover.

Air in clutch hydraulic system

Bleed air.

Fluid leakage from clutch fluid line

Locate leaking point and repair.

Worn synchronizer ring

Replace.

Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Distorted shift shaft

Replace.

Noise

Inadequate or insufficient lubricant

Replenish.

Damaged or worn bearing(s)

Replace.

Damaged or worn gear(s)

Replace.

Damaged or worn synchronizer ring

Replace.

Damaged or worn chamfered tooth on 
sleeve or gear

Replace.

5B-41 Manual Transmission/Transaxle: For Diesel Engine Model

Repair Instructions

Manual Transmission Assembly Components

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25

21

23

21

20

19

18

14

13

17

41

40

39

3

11

10

36

27

30

(h)

1

15

(c)

26

35

(g)

31

(b)

16 

16

33

(e)

42

6

(a)

8

(f)

16

31

(b)

7

(b)

7

(b)

38

(d)

37

(d)

34

(g)

29

(h)

24

9

4

9

2

32

12

5

12

28

27

27

22

(j)

I5JB0B520099-02

1. Transmission front case

: Apply sealant 99000-31110 to mating 
surface of front case and rear case.

19. Reverse shift limit cam spring

37. Reverse idle gear case No.1 bolt

2. Transmission rear case

: Apply sealant 99000-31110 to mating 
surface of rear case and adapter case.

20. Reverse shift shaft

38. Reverse idle gear case No.2 bolt

 3. Adapter case

21. Reverse idle gear washer

39. 5th & reverse gear shift yoke

Manual Transmission/Transaxle: For Diesel Engine Model 5B-42

4. Gear shift lever case assembly

: Apply sealant 99000-31110 to mating 
surface of gear shift lever case assembly 
and rear case.

22. Reverse idle gear needle bearing

40. High speed gear shift yoke

5. Adapter case oil seal

: Apply grease 99000-25010 to oil seal lip.

23. Reverse idle gear

41. Low speed gear shift yoke

6. Adapter case No.1 bolt

24. Reverse idle gear case

: Apply sealant 99000-31110 to mating 
surface of reverse idle gear case and rear 
case.

42. Input shaft bearing retainer oil 

seal
: Apply grease 99000-25010 to oil 
seal lip.

7. Adapter case No.2 bolt

25. Reverse idle gear shaft

: 54 N

⋅m (5.4 kgf-m, 39.0 lb-ft)

8. Gear shift lever case bolt

26. Back up light switch

: 45 N

⋅m (4.5 kgf-m, 32.5 lb-ft)

9. Select return bolt

: Apply sealant 99000-31110 to all around 
thread part of bolt

27. Washer

: 22 N

⋅m (2.2 kgf-m, 16.0 lb-ft)

10. Select return low speed spring (short)

28. Back up light switch pin

: Apply grease 99000-25010 to end of pin.

: 25  N

⋅m (2.5 kgf-m, 18.0 lb-ft)

11. Select return 5th & reverse spring (long)

29. Oil level/filler plug

: 26 N

⋅m (2.6 kgf-m, 19.0 lb-ft)

12. Select guide pin

30. Oil drain plug

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

13. Oil gutter

31. Transmission front case bolt

: 55 N

⋅m (5.5 kgf-m, 40.0 lb-ft)

14. Rear bearing plate

32. Input shaft bearing retainer

: Apply sealant 99000-31110 to mating 
surface of input shaft bearing retainer and 
front case.

: 35  N

⋅m (3.5 kgf-m, 25.5 lb-ft)

15. Rear bearing plate bolt

33. Input shaft bearing retainer bolt

: 39 N

⋅m (3.9 kgf-m, 28.5 lb-ft)

16. Pin

34. Transmission to engine bolt

: Do not reuse.

17. Gear shift & select lever assembly

35. Transmission to engine nut

: Apply transmission oil.

18. Reverse shift limit cam

36. Input shaft, main shaft & countershaft 

assembly