Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 351

5B-51 Manual Transmission/Transaxle: For Diesel Engine Model

4) Install gear shift case plate to gear shift lever case 

and tighten them to specified torque.

Tightening torque
Gear shift lever case plate screw:  6 N·m (0.6 kgf-
m, 4.5 lb-ft)

Gear Shift Lever Case Assembly Inspection

S6JB0A5226016

• Check that gear shift shaft moves smoothly without 

abnormal noise. If abnormality is found, replace 
defective part.

• Check bushes and boot for damage and deterioration. 

If abnormality is found, replace defective part.

Engine Rear Mounting Replacement

S6JB0A5226017

When replacement of mounting parts are necessary, 
torque bolts as specified below.

Tightening torque
Engine rear mounting No.1 bolt (a):  55 N·m (5.5 kgf-
m, 40.0 lb-ft)
Engine rear mounting member bolt (b):  55 N·m (5.5 
kgf-m, 40.0 lb-ft)
Engine rear mounting No.2 bolt (c):  55 N·m (5.5 kgf-
m, 40.0 lb-ft)

Manual Transmission Assembly Dismounting 
and Remounting

S6JB0A5226018

Dismounting

1) Disconnect negative (–) cable of battery.
2) Remove transmission shift control lever referring to 

“Transmission Shift Control Lever Removal and 
Installation: For Diesel Engine Model”.

3) Remove turbocharger inlet pipe (1), vacuum pump 

(2), engine hanger bracket, throttle body (3), noise 
suppressor wire (5) and air intake pipe (4).

CAUTION

!

 

When removing manual transmission, after 
remove turbocharger inlet pipe, noise 
suppressor wire and vacuum pump.
Otherwise, heater hoses, noise suppressor 
wire and vacuum pump is damaged.

 

1. Engine rear mounting member

2. Engine rear mounting

I5JB0A520015-01

1

4

2

3

I5JB0B520103-01

5

I5JB0B520017-02

Manual Transmission/Transaxle: For Diesel Engine Model 5B-52

4) Detach engine harness clamps and ground wire 

harness from transmission front case.

5) Remove starting motor fastening bolts and 

transmission fastening bolts.

6) Disconnect clutch fluid pipe from joint referring to 

“Clutch Fluid Pipe and Hose Removal and 
Installation in Section 5C”.

7) Hoist vehicle.
8) Drain oil from transmission and transfer.
9) Remove propeller shafts referring to “Propeller Shaft 

Removal and Installation in Section 3D”.

10) Remove exhaust No. 2 pipe.

11) Remove engine under cover.

12) Disconnect the following couplers and release their 

harness from clamps.
• CKP sensor
• Back up light switch
• Transfer shift actuator
• 4L/N switch
• Center differential lock switch

13) Remove clutch housing plate (1) and harness 

bracket (3).

14) Remove transmission fastening nut and bolts (2).

15) Apply transmission jack (1) and remove engine rear 

mounting member (2) taking off its bolts.

16) After removing mounting member, move rearward 

transmission and transfer assemblies placed on jack 
and then lower them.

17) Separate gear shift lever case assembly (2) and 

transfer assembly (3) from transmission assembly 
(1).

Remounting
For remounting, reverse dismounting procedure noting 
the following.
• Apply grease to input shaft.

“A”:  Grease 99000–25010 (SUZUKI Super Grease 
A)

• Slant the rear of the engine down, using support 

device (1) and install transmission to engine.

2

2

2

1

3

I5JB0B520105-01

2

1

I5JB0A520029-01

1

2

3

I5JB0B520019-01

“A”

I5JB0A520031-01

I3JA01520024-01

5B-53 Manual Transmission/Transaxle: For Diesel Engine Model

• Use specified torques as given below.

Tightening torque
Transmission to engine bolt and nut (a):  55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Engine rear mounting member bolt (b):  55 N·m (
5.5 kgf-m, 40.0 lb-ft)
Clutch housing plate bolt (c):  11 N·m (1.1 kgf-m, 
8.0 lb-ft)
Engine rear mounting No.2 bolt (d):  55 N·m (5.5 
kgf-m, 40.0 lb-ft)

• Set each clamp for wiring and hose securely.
• Install noise suppressor wire (1) at specified position 

as shown in figure.

• Install shift control lever referring to “Transmission 

Shift Control Lever Removal and Installation: For 
Diesel Engine Model”.

• Connect clutch fluid joint to pipe of clutch operating 

cylinder assembly referring to “Clutch Operating 
Cylinder Assembly Removal and Installation in 
Section 5C”.

• Install exhaust No.2 pipe referring to “Exhaust System 

Components: For Diesel Engine Model in Section 1K”.

• Fill gear oil to transmission referring to “Manual 

Transmission Oil Change: For Diesel Engine Model”.

• Fill gear oil to transfer referring to “Transfer Oil 

Change: Motor-Shift Type (Transfer with Shift 
Actuator) in Section 3C”.

• Connect battery and check function of engine, clutch, 

transmission and transfer.

• Install propeller shafts referring to “Propeller Shaft 

Removal and Installation in Section 3D”.

Manual Transmission Unit Disassembly

S6JB0A5226019

1) Remove clutch operating cylinder assembly from 

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

2) Remove reverse idle gear case (1) from rear case 

(2).

3) Remove back up light switch (1), washer and pin 

from front case (2).

[A]: Forward

2. Installation position (90

°)

(a)

(b)

(b)

(d)

(a)

(c)

(a)

I5JB0B520021-01

2

[A]

1

I5JB0B520020-01

2

1

I5JB0B520022-01

2

1

I5JB0B520023-01

Manual Transmission/Transaxle: For Diesel Engine Model 5B-54

4) Remove select return bolt (3), springs and guide 

pins, and then remove adapter case (1) from rear 
case (2).

5) Drive out each gear shift yoke pin (3) using special 

tool and then remove each gear shift yoke (1) and 
gear shift & select lever assembly (2).

Special tool
(A):  09922–85811

6) Drive out reverse shift limit cam pin (3) using special 

tool and then remove reverse shift limit cam (1) and 
spring (2).

Special tool
(A):  09922–85811

7) Remove rear bearing plate (1), oil gutter (2) and 

reverse shift shaft (3) from rear case (4).

8) Remove rear main shaft circlip (1) from rear case (3) 

using snap ring pliers (2).

9) Remove locating bolts (1) from rear case (2), then 

take out locating springs and balls.

3

1

3

2

I5JB0B520024-01

2

1

3

(A)

I5JB0B520025-01

1

3

2

I5JB0B520026-01

2

3

4

1

I5JB0B520027-01

2

1

3

I5JB0B520028-01

1

2

I5JB0B520029-01