Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 354

5B-63 Manual Transmission/Transaxle: For Diesel Engine Model

• Check clearance “d” between synchronizer center 

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

Clearance “d” between synchronizer center cone 
and gear (2nd and 3rd)
Standard: 0.2 – 0.9 mm (0.008 – 0.035 in.)
Service limit: 0.1 mm (0.004 in.)

• Check clearance “e” between synchronizer inner ring 

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

Clearance “e” between synchronizer inner ring 
and gear (2nd and 3rd)
Standard: 0.7 – 1.5 mm (0.028 – 0.059 in.)
Service limit: 0.3 mm (0.012 in.)

• Check clearance “a” between fork (1) and sleeve (2). 

Replace those parts if it exceeds limit.

NOTE
For correct judgement of parts replacement, 
carefully inspect contact portion of fork and 
sleeve.

 

Clearance “a” between fork and sleeve
Standard: 0.05 – 0.25 mm (0.002 – 0.010 in.)
Service limit: 0.45 mm (0.018 in.)

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

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

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

• Check chamfered part of each sleeve for damage and 

excessive wear, and replace as necessary.

• Check each synchronizer key and synchronizer key 

spring 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.

2

2

1

“d”

I5JB0B520066-03

1

2

2

1

“e”

I5JB0B520067-03

I5JB0B520068-01

2

3

1

I5JB0B520069-01

Manual Transmission/Transaxle: For Diesel Engine Model 5B-64

Main Shaft Reassembly

S6JB0A5226024

NOTE

• Before installation, wash each part and 

apply specified gear oil to sliding faces of 
bearing and gear.

• Use new circlips on shaft for installation. 

Do not reuse circlips.

 

1) Clean all components thoroughly, inspect them for 

any abnormality and replace with new one as 
necessary.

2) Apply oil to reverse gear needle bearing (1), and 

then install needle bearing, reverse gear (2) and 
reverse gear synchronizer ring (3) to main shaft.

3) Assemble 5th & reverse synchronizer sleeve (4), 

synchronizer key (5), synchronizer key spring (6) 
and hub (7) as shown in figure.

4) Drive in 5th & reverse synchronizer assembly (1) 

using bearing puller, special tools and hydraulic 
press.

Special tool
(A):  09913–85210
(B):  09945–55410
(C):  09940–54910

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

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

Available circlip thickness

6) Apply oil to 5th gear needle bearing, and then install 

needle bearing, 5th gear (1) and 5th gear 
synchronizer ring to main shaft.

7) Drive in main shaft bearing (2) using bearing puller, 

special tools and hydraulic press.

Special tool
(A):  09913–85210
(B):  09945–55410

I5JB0B520107-01

1.86 mm (0.073 in.)

2.04 mm (0.080 in.)

1.95 mm (0.077 in.)

(A)

(B)

(C)

1

I5JB0B520071-01

I5JB0B520072-02

(A)

(B)

2

1

I5JB0B520073-01

5B-65 Manual Transmission/Transaxle: For Diesel Engine Model

8) 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

9) Apply oil to 1st gear needle bearing (1), and then 

install needle bearing, 1st gear (2) and 1st gear 
synchronizer ring assembly (3) to main shaft.

10) Assemble low speed synchronizer sleeve (4), key 

(5), key spring (6) and hub (7) as shown in figure.

11) Drive in low speed synchronizer assembly (1) using 

bearing puller, special tools and hydraulic press, in 
specified direction as shown in figure.

Special tool
(A):  09913–85210
(B):  09940–54910

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

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

Available circlip thickness

1.77 mm (0.070 in.)

2.04 mm (0.080 in.)

1.86 mm (0.073 in.)

2.13 mm (0.084 in.)

1.95 mm (0.077 in.)

2.22 mm (0.087 in.)

I5JB0B520074-02

I5JB0B520075-01

[A]: 1st gear side

1.86 mm (0.073 in.)

2.04 mm (0.080 in.)

1.95 mm (0.077 in.)

1

(B)

(A)

1

[A]

I5JB0B520076-02

I5JB0B520077-02

Manual Transmission/Transaxle: For Diesel Engine Model 5B-66

13) Apply oil to 2nd gear needle bearing, and then install 

2nd gear synchronizer ring assembly, needle 
bearing and 2nd gear (1) to main shaft.

14) Drive in 3rd gear bush (2) using bearing puller, 

special tool and hydraulic press.

Special tool
(A):  09913–85210

15) Apply oil to 3rd gear needle bearing (1), and then 

install needle bearing, 3rd gear (2) and 3rd gear 
synchronizer ring assembly (3) to main shaft.

16) Assemble high speed synchronizer sleeve (4), key 

(5), key spring (6) and hub (7) as shown in figure.

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

bearing puller, special tools and hydraulic press, in 
specified direction as shown in figure.

Special tool
(A):  09913–84510

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

synchronizer hub 0.105 mm (0.004 in) or less and 
install it.

Available circlip thickness

(A)

2

1

I5JB0B520078-02

I5JB0B520108-01

[A]: 3rd gear side

1.500 mm (0.059 in.)

1.635 mm (0.064 in.)

1.545 mm (0.061 in.)

1.680 mm (0.066 in.)

1.590 mm (0.063 in.)

1.725 mm (0.068 in.)

1

(A)

1

[A]

I5JB0B520080-03

I5JB0B520081-01