Suzuki Grand Vitara JB416 / JB420. Manual - part 254

5B-12 Manual Transmission/Transaxle:

Installation

1) Install gear shift control lever rear case assembly

with its plate to transfer case referring to figure for
proper installing direction of control shaft joint bolt
(2). Tighten plate bolts (1) and control shaft joint nut
(3) to specified torque.

Tightening torque
Plate bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Control shaft joint nut (b): 18 N·m (1.8 kgf-m,
13.0 lb-ft)

2) Remount transmission assembly to vehicle referring

to “Manual Transmission Assembly Dismounting and
Remounting”

Gear Shift Control Lever Rear Case Assembly
Disassembly and Reassembly

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Disassembly and reassembly component parts referring
to “Gear Shift Control Lever Rear Case Assembly
Components”.

Gear Shift Control Lever Rear Case Assembly
Inspection

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• Check that gear shift control shaft moves smoothly

without abnormal noise. If abnormality is found,
replace defective part.

• Check bush and boot for damage and deterioration. If

abnormality is found, replace defective part.

Gear Shift Lever Front Case Assembly Removal
and Installation

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Removal

1) Dismount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting”

2) Remove gear shift lever front case assembly (1)

from transmission rear case.

Installation

NOTE

• Install gear shift lever front case to

transmission rear case without using
sealant for functional check.

• Install shift control lever and check to

make sure that it shifts smoothly
according to shift pattern as shown in the
figure.

1, (a)

3, (b)

I5JB0A520008-03

I5JB0A520009-03

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Manual Transmission/Transaxle: 5B-13

1) Clean mating surface of both rear case and gear

shift lever front case (2), and uniformly apply sealant
to lever case as shown in figure by such amount that
its section is 1.2 mm (0.047 in.) in diameter, and then
mate it with gear shift lever front case.

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

2) Install lever case to rear case and then tighten new

lever case bolts (1) to specified torque.

Tightening torque
Gear shift lever front case bolt (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)

3) Connect gear shift shaft (3) of lever case assembly

to gear shift control shaft (4) of gear shift control
lever rear case assembly referring to figure for
proper installing direction of control shaft joint bolt
(5). Tighten control shaft joint nut (6) to specified
torque.

Tightening torque
Control shaft joint nut (b): 18 N·m (1.8 kgf-m,
13.0 lb-ft)

4) Remount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting”

Gear Shift Lever Front Case Assembly
Disassembly and Reassembly

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Disassembly

1) Remove gear shift case plug.
2) Drive out gear shift arm pin using special tool, and

then disassemble components parts.

CAUTION

Be careful to disconnect gear shift shaft from
gear shift lever front case so that gear shift
locating ball and gear shift locating spring
may be jumped out.

Special tool
(A): 09925–78210

Reassembly

1) Install new gear shift shaft oil seal (1) to gear shift

lever front case using special tool.

Special tool
(A): 09923–46020

1, (a)

6, (b)

“A”

I5JB0A520011-04

(A)

I5JB0A520012-01

(A)

I5JB0A520013-01

5B-14 Manual Transmission/Transaxle:

2) Assemble components parts referring to “Gear Shift

Lever Front Case Assembly Components”.

3) Set new gear shift arm inner pin (1) and outer pin (2)

facing each gap (“a”, “b”) as shown in figure.
Drive gear shift arm pins by using special tool, till the
length “c” becomes the specified. (The length “c” is
the length of the pin protrusion from gear shift shaft
(4) and select arm (3)).

Special tool
(A): 09925–78210

Gear shift arm pin protrusion “c”: 0.5–1.5 mm
(0.020–0.059 in.)

Gear Shift Lever Front Case Assembly
Inspection

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• 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

S5JB0A5206010

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

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Dismounting

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

“Transmission Shift Control Lever Removal and
Installation”.

3) Detach engine harness clamps and ground wire

harness from transmission front case.

4) Remove starting motor fastening bolts (2) and

transmission fastening bolts (1).

5. Case side

“a”

“b”

(A)

“c”

1, 2

I5JB0A520014-01

1. Engine rear mounting member
2. Engine rear mounting

I5JB0A520015-01

I5JB0A520016-01

Manual Transmission/Transaxle: 5B-15

5) Disconnect clutch fluid joint from pipe of clutch

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

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

Removal and Installation in Section 3D”.

9) Remove exhaust No. 2 pipe.

10) Remove engine under cover.

11) Remove clutch housing lower plates (1).

12) Remove transmission fastening nut (2) and bolts (3).

13) Disconnect the following couplers and release their

harness from clamps.
• Back up light switch
• Transfer shift actuator (for J20 engine model)
• 4L/N switch (for J20 engine model)
• Center differential lock switch (for J20 engine

model)

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

mounting member (2) taking off its bolts.

15) After removing mounting member, move rearward

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

16) Separate gear shift control lever rear case assembly

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

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