Suzuki Grand Vitara JB419. Service manual - part 110

Manual Transmission/Transaxle:  5B-16

• Install shift control lever referring to “Transmission 

Shift Control Lever Removal and Installation”.

• 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 in Section 1K”.

• Fill gear oil to transmission referring to “Manual 

Transmission Oil Change”.

• Fill gear oil to transfer referring to “Transfer Oil 

Change in Section 3C in related manual”.

• 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

S5JB0B5206019

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).

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

2

1

I5JB0B520022-01

2

1

I5JB0B520023-01

3

1

3

2

I5JB0B520024-01

2

1

3

(A)

I5JB0B520025-01

1

3

2

I5JB0B520026-01

5B-17 Manual Transmission/Transaxle: 

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.

10) Remove rear case to front case bolts (1), then 

separate rear case (2) from front case (3) using 
special tool.

Special tool
(A):  09912–34510

11) Drive out each gear shift shaft pin using special tool 

and then remove each gear shift shaft (1), fork (2), 
ball and inter lock pin.

Special tool
(A):  09922–85811

2

3

4

1

I5JB0B520027-01

2

1

3

I5JB0B520028-01

1

2

I5JB0B520029-01

1

2

3

(A)

1

1

1

I5JB0B520030-01

(A)

1

2

I5JB0B520031-01

Manual Transmission/Transaxle:  5B-18

12) Remove input shaft bearing retainer to front case 

bolt (1), then separate input shaft bearing retainer (2) 
from front case (3).

13) Remove oil seal (1) from input shaft bearing retainer 

(2) using flat end rod or the like, if necessary.

14) Remove input shaft front bearing circlip (1) from front 

case (3) using snap ring pliers (2).

15) Remove input shaft assembly, main shaft assembly 

(1) and countershaft assembly (2) all together from 
front case (3) tapping input shaft end by plastic 
hammer lightly.

Manual Transmission Unit Reassembly

S5JB0B5206020

1) Assemble input shaft assembly, main shaft assembly 

(1) and countershaft assembly (2), and then install 
them all together into front case (3).

2) Install new input shaft front bearing circlip (1) to front 

case using snap ring pliers (2)

3

1

1

1

2

I5JB0B520032-01

1

2

I5JB0B520033-01

1

2

3

I5JB0B520034-01

3

2

1

I5JB0B520035-01

3

2

1

I5JB0B520035-01

1

2

I5JB0B520036-02

5B-19 Manual Transmission/Transaxle: 

3) Install new oil seal (1) to input shaft bearing retainer 

(2) facing its spring side upward in figure using 
special tool and hammer and then apply grease to oil 
seal lip.

Special tool
(A):  09913–76010

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

Install position oil seal
“a”: 0 – 1.0 mm (0 – 0.0039 in.)

4) Clean mating surfaces of both input shaft bearing 

retainer (1) and front case (2), and uniformly apply 
sealant to input shaft bearing retainer as shown in 
figure by such amount that its section is 1.5 mm 
(0.059 in.) in diameter, and then mate it with front 
case.

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

5) Install input shaft bearing retainer to front case with 

new bolts. Tighten bolts (3) to specified torque.

Tightening torque
Input shaft bearing retainer bolt (a):  26 N·m (2.6 
kgf-m, 19.0 lb-ft)

6) Install low speed gear shift shaft (1) and low speed 

gear shift fork (2) to front case (3).

7) Apply grease to gear shift shaft balls (4), and then 

install it to hole of front case (5) between low speed 
gear shift shaft and high speed gear shift shaft.

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

8) Install 5th & reverse gear shift fork (1) and high 

speed gear shift fork (2) to front case (3).

9) Apply grease to inter lock pin (4), and install it to high 

speed gear shift shaft (5), and then install high speed 
gear shift shaft to front case.

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

10) Apply grease to gear shift shaft balls (1), and then 

install it to hole of front case (2) between high speed 
gear shift shaft and 5th & reverse gear shift shaft.

11) Install 5th & reverse gear shift shaft (3) to front case 

(4).

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

I5JB0B520038-01

“A”

1

3, (a)

3, (a)

3, (a)

2

I5JB0B520037-01

3

1

2

5

1

4, “A”

I5JB0B520039-01

3

2

1

5

5

4, “A”

I5JB0B520040-03

3

4

3

1, “A”

2

I5JB0B520041-02