Suzuki Grand Vitara JB627. Manual - part 244

5A-160 Automatic Transmission/Transaxle: 

Special Tools and Equipment

Recommended Service Material

S6JB0B5108001

NOTE
Required service material is also described in the following.
“Automatic Transmission Unit Components”
“Oil Pump Assembly Components”
“Clutch Drum & Input Shaft Assembly Components”

 

Special Tool

S6JB0B5108002

Material

SUZUKI recommended product or Specification

Note

Sealant

SUZUKI Bond No.1216B

P/No.: 99000–31230

)

 / )

09900–06108

09913–50121

Snap ring pliers (closing 
type)

Oil seal remover

)

 / ) / ) / )

)

09913–75520

09913–75810

Bearing installer

Bearing installer

)

)

09913–85210

09916–57330

Bearing installer

Valve guide installer handle

)

 / )

)

09917–98221

09920–13120

Valve guide stem 
attachment

Crankcase separator

)

)

 / ) / )

09920–20310

09922–86010

Clutch spring hook

Clutch piston compressor

)

 / )

)

 / )

09922–89810

09925–37811–001

Shifter lock pin remover (3.5 
mm)

Oil pressure gauge

)

)

Automatic Transmission/Transaxle:  5A-161

09926–96040

09926–96520

Clutch spring compressor 
No.8

Spring compressor

)

 / ) / ) / )

)

 / )

09927–66510

09927–66520

Spring compressor

Oil pump remover

)

)

09927–66530

09927–66540

Spring compressor

Spring compressor

)

)

 / )

SUZUKI scan tool
—
This kit includes following 
items. 1. Tech 2, 2. PCMCIA 
card, 3. DLC cable, 4. SAE 
16/19 adapter, 5. Cigarette 
cable, 6. DLC loop back 
adapter, 7. Battery power 
cable, 8. RS232 cable, 9. 
RS232 adapter, 10. RS232 
loop back connector, 11. 
Storage case, 12. ) / ) / )

5B-1 Manual Transmission/Transaxle: 

Transmission / Transaxle

Manual Transmission/Transaxle

General Description

Manual Transmission Construction

S6JB0B5201001

The manual transmission consists of the input shaft, output shaft, countershaft and reverse idle gear shaft which are 
installed in the die-cast aluminum alloy case. This transmission provides five forward speeds and one reverse speed.
The 1st, 2nd, 3rd and 4th speeds are for speed reduction drive, 5th speed is for direct drive. The low speed (1st and 
2nd) synchronizer is mounted on the countershaft and engaged with the countershaft 1st or 2nd gear. The high speed 
(3rd and 4th) synchronizer is mounted on of the input shaft and engaged with the input shaft 3rd and 4th gear. The 5th 
speed synchronizer is mounted on the input shaft and engaged with the output shaft. The gear shift lever case is 
located at the upper behind the transmission case and has a cam which prevents direct gear shifting from the 5th 
speed gear into the reverse gear.
As the die-cast aluminum alloy case are sealed with liquid type gasket, it is necessary to use genuine sealant or its 
equivalent on its mating surface when reassembling them. Also, the case fastening bolts must be tightened to 
specified torque by means of the torque wrench and tightening over or below the specified torque should be avoided.
The description under “Repair Instructions” covers the transfer partially which is next to the transmission as well, but 
their gear boxes are independent and each of them has its own drain and filler plugs for the oil change or the level 
check.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

I5JB0A520017-02

1. Input shaft

7. 3rd gear

13. Countershaft

2. Transmission front case

8. Gear shift shaft

14. 2nd gear

3. Reverse idler gear

9. Output shaft gear

15. Transmission rear case

4. Reverse shaft

10. Adapter case

16. Low speed synchronizer hub

5. 4th gear

11. Output shaft

17. 1st gear

6. High speed synchronizer hub

12. 5th speed synchronizer hub

18. Reverse gear

Manual Transmission/Transaxle:  5B-2

Diagnostic Information and Procedures

Manual Transmission Symptom Diagnosis

S6JB0B5204001

Condition

Possible cause

Correction / Reference Item

Gear slipping out of mesh Worn shift fork shaft

Replace.

Worn shift fork or synchronizer sleeve

Replace.

Weak or damaged locating spring

Replace.

Worn bearings on input shaft, 
countershaft or output shaft

Replace.

Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Missing or disengagement of snap 
ring(s)

Install or replace.

Gears refusing to 
disengage

Weakened or broken synchronizer 
spring

Replace.

Distorted shift shaft or shift fork

Replace.

Hard shifting

Improper clutch pedal free travel

Replace pedal arm and/or clutch master 
cylinder.

Distorted or broken clutch disc

Replace.

Damaged clutch pressure plate

Replace clutch cover.

Air in clutch hydraulic system

Bleed air.

Fluid leakage from clutch fluid line

Locate leaking point and repair.

Worn synchronizer ring

Replace.

Worn chamfered tooth on sleeve or gear Replace sleeve and gear.
Distorted shift shaft

Replace.

Noise

Inadequate or insufficient lubricant

Replenish.

Damaged or worn bearing(s)

Replace.

Damaged or worn gear(s)

Replace.

Damaged or worn synchronizer ring

Replace.

Damaged or worn chamfered tooth on 
sleeve or gear

Replace.