Suzuki Grand Vitara JB416 / JB420. Manual - part 256

5B-20 Manual Transmission/Transaxle: 

14) Install output shaft assembly into rear case.
15) Select a countershaft shim and output shaft shim as 

follows.
a) Measure depth “a” from mating surface of 

adapter case (1) to face processed for 
installation of countershaft rear bearing (2) and 
measure depth “c” from mating surface of 
adapter case to face processed for installation of 
output shaft rear bearing (5) using vernier 
caliper.

b) Measure height “b” from mating surface of rear 

case (3) to countershaft rear bearing (2) and “d” 
from mating surface of rear case (3) to output 
shaft bearing (6) using vernier caliper.

c) Calculate “a” – “b” and “c” – “d”, and select a 

shim according to the following table.

Countershaft shim selection table

Output shaft shim selection table

16) Install selected countershaft shim and output shaft 

shim to adapter case.

17) Clean mating surface of both rear case (1) and 

adapter case, and uniformly apply sealant to rear 
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 adapter case.

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

Clearance “a” – “b”

Thickness of 

countershaft shim

1.15 – 1.24 mm

(0.046 – 0.048 in.)

0.90 mm (0.035 in.)

1.25 – 1.34 mm

(0.050 – 0.052 in.)

1.00 mm (0.039 in.)

1.35 – 1.44 mm

(0.054 – 0.056 in.)

1.10 mm (0.043 in.)

1.45 – 1.54 mm

(0.057 – 0.060 in.)

1.20 mm (0.047 in.)

1.55 – 1.64 mm

(0.061 – 0.064 in.)

1.30 mm (0.051 in.)

1.65 – 1.74 mm

(0.065 – 0.068 in.)

1.40 mm (0.055 in.)

1.75 – 1.84 mm

(0.069 – 0.072 in.)

1.50 mm (0.059 in.)

1.85 – 1.94 mm

(0.073 – 0.076 in.)

1.60 mm (0.063 in.)

1.95 – 2.04 mm

(0.077 – 0.080 in.)

1.70 mm (0.067 in.)

2.05 – 2.14 mm

(0.081 – 0.084 in.)

1.80 mm (0.071 in.)

2.15 – 2.24 mm

(0.085 – 0.088 in.)

1.90 (0.90 + 1.00) mm 

(0.075 (0.035 + 0.039) in.)

Clearance “c” – “d”

Thickness of 

countershaft shim

0 – 0.09 mm (0 – 0.04 in.)

—

0.1 – 0.19 mm

(0.004 – 0.007 in.)

0.1 mm (0.004 in.)

0.2 – 0.29 mm

(0.008 – 0.011 in.)

0.2 mm (0.008 in.)

0.3 – 0.39 mm

(0.012 – 0.015 in.)

0.3 mm (0.012 in.)

0.4 – 0.49 mm

(0.016 – 0.019 in.)

0.4 mm (0.016 in.)

0.5 – 0.59 mm

(0.020 – 0.023 in.)

0.5 mm (0.020 in.)

0.6 – 0.69 mm

(0.024 – 0.027 in.)

0.6 mm (0.024 in.)

0.7 – 0.79 mm

(0.028 – 0.031 in.)

0.7 mm (0.028 in.)

“a”

“b”

“d”

2

“c”

5

1

3

4

6

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Manual Transmission/Transaxle:  5B-21

18) Install rear case to adapter case. Tighten case bolts 

(2) to specified torque.

Tightening torque
Adapter case bolt (a):  23 N·m (2.3 kgf-m, 17.0 lb-
ft)

19) Install transfer assembly to transmission assembly. 

Tighten transfer fastening bolts to specified torque 
referring to “Transfer Assembly Components: Motor-
Shift Type (Transfer with Shift Actuator) in Section 
3C” or “Transfer Assembly Components: Non-Shift 
Type (Transfer without Shift Actuator) in Section 3C”.

20) Install gear shift control lever rear case assembly 

and gear shift lever front case assembly referring to 
“Gear Shift Control Lever Rear Case Assembly 
Removal and Installation” and “Gear Shift Lever 
Front Case Assembly Removal and Installation”.

21) 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 Disassembly

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1) Remove snap ring.
2) Remove input shaft front bearing (1) using bearing 

puller and hydraulic press.

3) Remove input shaft union.
4) Hold hatched area (5) of input shaft assembly (1) 

with “V” blocks (4) on vise (2) or the like to stop 
rotation of shaft, undo caulking and input shaft 5th 
hub nut (3).

CAUTION

!

 

Do not hold spline, gear teeth or abrasived 
surface of shaft with vise through “V” blocks 
or the like, otherwise shaft components may 
be damaged.

 

5) Apply bearing puller to 4th gear (1), and drive out 5th 

speed synchronizer hub (2), 3rd gear (3), high speed 
gear needle bearings, 3rd gear bush, high speed 
synchronizer assembly (4) and 4th gear all at once 
from input shaft using metal stick (5) and press.

CAUTION

!

 

To avoid gear teeth from being damaged, 
support 4th gear at flat side of bearing puller.

 

2, (a)

2, (a)

2, (a)

2, (a)

“A”

1

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1

2

3

5

4

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2

3

1

5

4

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5B-22 Manual Transmission/Transaxle: 

Input Shaft Inspection

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• Check clearance “a” between synchronizer ring (2) 

and gear (1), key slot width “b” in synchronizer ring 
and each chamfered tooth of gear and synchronizer 
ring and replace with new one, if necessary. Also, 
check gear tooth.

Clearance “a” between synchronizer ring and 
gear (Input shaft) (3rd and 4th)
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)

Key slot width “b” (3rd and 4th synchronizer ring)
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)

• Measure width of high speed gear shift fork end “a” 

and groove width of high speed synchronizer sleeve 
“b”, 5th & reverse gear shift fork end “a” and groove 
width of 5th speed synchronizer sleeve “b” and then 
calculate clearance “c” as follows:

If clearance exceeds limit, replace fork bush (1) and 
sleeve.

Clearance “c” between fork and sleeve for high 
speed and 5th speed
Standard: 0.3 – 0.5 mm (0.012 – 0.020 in.)
Limit: 1.0 mm (0.039 in.)

• Check diameter of input shaft (1) and needle bush (2) 

as shown in the figure. If measured value is out of 
specification, replace input shaft and/or bush.

Input shaft and needle bush specifications 
(diameter)

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

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

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

Clearance “c”

=

“b”

–

“a”

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1

“a”

“b”

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Measuring 

portion

Standard

“a”

30.002 – 30.015 mm

(1.1812 – 1.1816 in.)

“b”

34.950 – 34.991 mm

(1.3760 – 1.3775 in.)

“c”

30.959 – 30.975 mm

(1.2189 – 1.2194 in.)

“d”

27.987 – 28.000 mm

(1.1018 – 1.1023 in.)

“e”

27.967 – 27.980 mm
(1.1011 – 1.1015 in.)

“f”

19.975 – 19.991 mm

(0.7865 – 0.7870 in.)

“g”

28.000 – 28.013 mm

(1.1024 – 1.1028 in.)

“h”

34.975 – 34.991 mm

(1.3770 – 1.3775 in.)

“c”

“d”

“e”

“f”

“g” “h”

“b”

“a”

1

2

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2

3

1

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Manual Transmission/Transaxle:  5B-23

• Using cylinder gauge (1), check inside diameter of 

each gear. If its inside diameter exceeds specification, 
replace it.

Inside diameter (standard) of gear
3rd and 4th gear: 40.000 – 40.025 mm (1.5748 – 
1.5757 in.)

• Check chamfered part of each sleeve for damage and 

excessive wear, and replace as necessary.

• Check each synchronizer key and synchronizer spring 

and replace as necessary.

• Check spline portions and replace parts if excessive 

wear is found.

Input Shaft Reassembly

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NOTE

• Before installation, wash each part and 

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

• Use new snap rings on shaft for 

installation. Don’t reuse snap rings.

 

1) Clean all components thoroughly, inspect them for 

any abnormality and replace with new ones as 
necessary.

2) To ensure lubrication, air blow oil holes (1) and make 

sure that they are free from any obstruction.

3) Drive in input shaft front bearing (1) to input shaft 

using special tool and hammer and then install snap 
ring in specified direction as shown in figure.

Special tool
(A):  09940–51710

NOTE
Input shaft front bearing circlip (2) must be 
installed before input shaft front bearing is 
installed.

 

4) Apply oil to high speed gear needle bearing (5), and 

then install needle bearing, 4th gear (5) and high 
speed synchronizer ring (7) to input shaft.

5) Assemble synchronizer sleeve (4) and hub (3) as 

follows.
a) Fit high speed synchronizer sleeve to hub in 

specified direction as shown in figure.

b) Insert 3 keys (2) to hub.
c) Set springs (1) at specified position as shown in 

figure.

Synchronizer key installation position
: A = B

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1

1

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A: Bearing side

[A]: 4th gear side

C: Key way
D: Projecting end

(A)

1

2

A

2

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