Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 340

5B-7 Manual Transmission/Transaxle: For Petrol Engine Model

Gear Shift Shaft and Fork Components

S6JB0A5216004

1322

5

6

7

A

A

6

4

7

A

A

6

7

A

A

6

7

A

A

1

2

3

8

8

8

(a)

1322

5

(a)

1322

5

(a)

1322

5

(a)

I5JB0A520002-02

1. Low speed gear shift shaft

4. Low speed gear shift fork

7. Gear shift shaft ball

: Apply grease 99000-25010 to ball.

2. High speed gear shift fork

5. Gear shift locating bolt

: Apply thread lock 99000-32110 to bolt thread.

8. Gear shift fork bush

3. 5th & reverse gear shift fork

: Never disassemble.

6. Gear shift locating spring

: Apply grease 99000-25010 to spring.

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

Manual Transmission/Transaxle: For Petrol Engine Model 5B-8

Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components

S6JB0A5216005

6

4

3

2

18

24

25

34

35

37

36

26

27

28

30

31

29

32

33

30

29

19

20

21

22

5

1

7

9

8

10

11

12

9

8

13

14

17

23        

[A]

[B]

[C]

OIL

15

16

OIL

OIL

OIL

(a)

(a)

38

39

40

OIL

OIL

OIL

OIL

OIL

I6JB01520012-01

[A]: Input shaft assembly

14. 5th speed synchronizer hub

30. Low speed synchronizer spring

[B]: Output shaft assembly

15. High speed gear needle bearing

31. Low speed synchronizer key

[C]: Countershaft assembly

16. Input shaft 3rd gear bush

32. Low speed synchronizer hub

1. Snap ring

17. Input shaft 5th hub nut

33. Low speed synchronizer sleeve

2. Input shaft front bearing

18. Output shaft

34. Countershaft gear needle bearing

3. Input shaft front bearing circlip

19. Output shaft front bearing

35. 2nd gear

4. Input shaft

20. Output shaft gear

36. Countershaft

5. Input shaft union

21. Output shaft rear bearing

37. Countershaft rear bearing

5B-9 Manual Transmission/Transaxle: For Petrol Engine Model

Manual Transmission Oil Change

S6JB0A5216006

1) Before changing or inspecting oil, be sure to stop 

engine and lift vehicle horizontally.

2) With vehicle lifted up, check oil level and leakage. If 

leakage exists, correct or repair it.

NOTE
Whenever vehicle is hoisted for any other 
service work than oil change, also be sure to 
check for oil leakage.

 

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten 

it to specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Transmission oil drain plug (a):  23 N·m (2.3 kgf-
m, 17.0 lb-ft)

NOTE
If water or rust is mixed in drained oil, be 
sure to check breather hose and boot of 
transmission.

 

6) Pour new specified oil until oil level reaches bottom 

of oil filler plug hole (3) as shown in figure.

NOTE
It is highly recommended to use API 75 W-90 
gear oil.

 

Gear oil specifications
: API GL-4 (For SAE classification, refer to 
viscosity chart [A] in figure.)

Manual transmission oil capacity
Reference: 1.9 liters (4.0/3.3 US/Imp. pt)

7) Apply sealant to thread of filler plug, and then tighten 

it to specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Oil filler plug (b):  23 N·m (2.3 kgf-m, 17.0 lb-ft)

6. High speed gear needle bearing

22. Output shaft rear snap ring

38. 5th speed synchronizer sleeve

7. 4th gear

23. Countershaft front bearing nut

39. 5th speed synchronizer lever

8. High speed synchronizer ring

24. Countershaft front bearing

40. 5th speed synchronizer ring

9. High speed synchronizer spring

25. Countershaft reverse gear

: 210 N

⋅m (21.0 kgf-m, 152.0 lb-ft)

10. High speed synchronizer sleeve

26. Countershaft low needle bush

: Do not reuse.

11. High speed synchronizer key

27. Countershaft gear needle bearing

: Apply transmission oil.

12. High speed synchronizer hub

28. 1st gear

13. 3rd gear

29. Low speed synchronizer ring

2, (b),  “A”

1, (a),  “A”

I5JB0A520020-01

I5JB0A520022-02

80W-90

Temperature

-30

C

o

F

o

-20

-10

0

10

20

30

40

-22

-4

14

32

50

68

86

104

75W-85, 75W-90

[A]

I5JB0A520021-02

Manual Transmission/Transaxle: For Petrol Engine Model 5B-10

Extension Case Oil Level Check

S6JB0A5216036

1) Lift up vehicle and check oil leakage.
2) Remove oil level / filler plug (1) and check oil level is 

lower end of oil level / filler plug hole (2).
If oil level is not lower end of oil level / filler plug hole, 
add specified oil up to plug hole.

Extension Case Oil Change

S6JB0A5216031

1) Before changing or inspecting oil, be sure to stop 

engine and lift vehicle horizontally.

2) With vehicle lifted up, check oil level and leakage. If 

leakage exists, correct or repair it.

NOTE
Whenever vehicle is hoisted for any other 
service work than oil change, also be sure to 
check for oil leakage.

 

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten 

it to specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Extension case oil drain plug (a):  23 N·m (2.3 
kgf-m, 17.0 lb-ft)

NOTE
If water or rust is mixed in drained oil, be 
sure to check breather hose of extension 
case.

 

6) Pour new specified oil until oil level reaches bottom 

of oil filler plug hose (3) as shown in figure.

NOTE
It is highly recommended to use API 75 W-90 
gear oil.

 

Gear oil specifications
: API GL-4 (For SAE classification, refer to 
viscosity chart [A] in figure.)

Extension case oil capacity (Reference)
0.4 liters (0.8/0.7 US/lmp. pt)

7) Apply sealant to thread of filler plug, and then tighten 

it to specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Extension case oil filler plug (b):  23 N·m (2.3 
kgf-m, 17.0 lb-ft)

1

I6JB01520016-02

I6JB01520014-01

2, (b), “A”

1, (a), “A”

I6JB01520001-01

I5JB0A520022-02

80W-90

Temperature

-30

C

o

F

o

-20

-10

0

10

20

30

40

-22

-4

14

32

50

68

86

104

75W-85, 75W-90

[A]

I5JB0A520021-02