Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 353

5B-59 Manual Transmission/Transaxle: For Diesel Engine Model

22) Clean mating surfaces of both rear case (1) and 

adapter case (2), and uniformly apply sealant to rear 
case as shown in figure by such amount that its 
section is 1.5 mm (0.059 in.) in diameter, and then 
mate it with adapter case.

“A”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)

23) Install rear case to adapter case. Tighten adapter 

case No.1 bolts (3) and new adapter case No.2 bolt 
(4) to specified torque.

Tightening torque
Adapter case No.1 bolt (a):  45 N·m (4.5 kgf-m, 
32.5 lb-ft)
Adapter case No.2 bolt (b):  54 N·m (5.4 kgf-m, 
39.0 lb-ft)

24) Clean mating surfaces of both reverse idle gear case 

(1) and rear case (2), and uniformly apply sealant to 
reverse idle gear case as shown in figure by such 
amount that its section is 1.5 mm (0.059 in.) in 
diameter, and then mate it with rear case.

“A”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)

25) Install reverse idle gear case to rear case with new 

bolts. Tighten No.1 bolts (3) and No.2 bolts (4) to 
specified torque.

Tightening torque
Reverse idle gear case No.1 bolt and No.2 bolt 
(a):  26 N·m (2.6 kgf-m, 19.0 lb-ft)

26) Apply grease to select guide pins (1), and then install 

select guide pins, select return low speed spring 
(short) (2) and select return 5th & reverse spring 
(long) (3). Apply sealant to select return bolts, and 
then tighten bolts (4) to specified torque.

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A)
“B”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)

Tightening torque
Select return bolt (a):  25 N·m (2.5 kgf-m, 18.0 lb-
ft)

1

2

3, (a)

4, (b)

3, (a)

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2

“A”

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3, (a)

2

1

4, (a)

3, (a)

1

“A”

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4, “B”, (a)

4, “B”, (a)

1, “A”

2

3

1, “A”

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Manual Transmission/Transaxle: For Diesel Engine Model 5B-60

27) Install buck up light switch (1), new washer and pin 

to front case (2) referring to “Back Up Light Switch 
Removal and Installation: For Diesel Engine Model”.

28) Install clutch operating cylinder assembly to 

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

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 Assembly Disassembly and 
Reassembly

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Disassembly

1) Remove input shaft circlip from input shaft using 

snap ring pliers.

2) Remove input shaft bearing (1) from input shaft (2) 

using bearing puller and hydraulic press.

Reassembly

1) Clean all components thoroughly, inspect them for 

any abnormality and replace with new ones as 
necessary.

2) Drive in input shaft bearing (1) onto input shaft facing 

groove (2) side to downward in figure (3) using 
special tool and hydraulic press.

Special tool
(A):  09913–75520

3) Select circlip (1) that will make thrust clearance “a” of 

bearing 0.15 mm (0.006 in) or less and install it.

Available circlip thickness

Input Shaft Inspection

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• Check chamfered teeth of gear for damage and 

excessive wear, and replace as necessary.

• Check spline portions and replace parts if excessive 

wear is found.

• Check bearing for smooth rotation and replace it if 

abnormality is found.

1

2

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2

1

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1.89 mm (0.074 in.)

2.07 mm (0.081 in.)

1.98 mm (0.078 in.)

(A)

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2

3

2

1

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5B-61 Manual Transmission/Transaxle: For Diesel Engine Model

Main Shaft Disassembly

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1) Remove main shaft bearing circlip using snap ring 

pliers.

2) Remove main shaft bearing (1) from main shaft (2) 

using bearing puller and hydraulic press.

3) Remove circlip (1) using snap ring pliers (2) and then 

pull out high speed synchronizer sleeve (5) from high 
speed synchronizer hub gradually with holding down 
synchronizer key (3) in order to prevent synchronizer 
keys and springs (4) from jumping out.

4) Remove high speed synchronizer hub (1), 3rd gear 

synchronizer ring assembly (2), 3rd gear (3), 3rd 
gear needle bearing, 3rd gear bush and 2nd gear (4) 
from main shaft (5) using special tool, bearing puller 
and hydraulic press.

Special tool
(A):  09925–98220

5) Remove 2nd gear needle bearing and 2nd gear 

synchronizer ring assembly.

6) Remove circlip (1) using snap ring pliers (2) and then 

pull out low speed synchronizer sleeve (3) from low 
speed synchronizer hub gradually with holding down 
synchronizer key in order to prevent synchronizer 
keys (4) and synchronizer key springs (5) from 
jumped out.

7) Remove low speed synchronizer hub (1), 1st gear 

synchronizer ring assembly (2) and 1st gear (3) 
using bearing puller and hydraulic press, and then 
1st gear needle bearing.

8) Remove 5th gear, synchronizer ring and needle 

bearing.

9) Remove circlip (1) using snap ring pliers (2) and then 

pull out 5th & reverse synchronizer sleeve (3) from 
5th & reverse synchronizer hub gradually with 
holding down synchronizer key in order to prevent 
synchronizer keys and springs from jumped out.

2

1

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1

3

4

2

5

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2

1

5

(A)

4

3

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3

5

4

2

1

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1

2

3

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1

2

3

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Manual Transmission/Transaxle: For Diesel Engine Model 5B-62

10) Remove reverse gear (1), reverse gear synchronizer 

ring and 5th & reverse synchronizer hub (2) using 
bearing puller and hydraulic press, and then reverse 
gear needle bearing.

Main Shaft Inspection

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• Check clearance “a” between synchronizer outer ring 

(1) and gear (2) while lightly pushing synchronizer ring 
by hand, and also check chamfered tooth of gear and 
synchronizer outer ring. Also, check gear tooth. 
Replace with new one if necessary.

Clearance “a” between synchronizer outer ring 
and gear (4th, 5th and reverse)
Standard: 1.0 – 1.5 mm (0.040 – 0.059 in.)
Service limit: 0.7 mm (0.028 in.)

• Put synchronizer outer ring (1), inner ring (2) and 

center cone (3) together and then measure step 
difference “b” between outer ring and inner ring using 
straight edge (4). And also check chamfered tooth of 
gear and synchronizer ring. Also, check gear tooth. 
Replace with new one if necessary.

Difference “b” between synchronizer outer ring 
and center cone (1st)
Standard: 0.4 – 0.8 mm (0.016 – 0.031 in.)
Service limit: 0.2 mm (0.008 in.)

• Check clearance “c” between synchronizer outer ring 

(1) and center cone (2). If clearance exceeds limit, 
replace with new one.

Clearance “c” between synchronizer outer ring 
and center cone (1st, 2nd and 3rd)
Standard: 0.41 – 0.7 mm (0.016 – 0.028 in.)
Service limit: 0.3 mm (0.012 in.)

1

2

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1

2

1

2

“a”

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4

4

1

1

3

2

“b”

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1

2

1

“c”

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