General Description - Suzuki Grand Vitara XL-7 Service Manual

7A2-2 MANUAL TRANSMISSION

GENERAL DESCRIPTION

The manual transmission consists of the input shaft, main shaft, countershaft and reverse idler shaft which are
installed in the die-cast aluminum alloy and cast-iron cases. This transmission provides five forward speeds and
one reverse speed.
The 1st, 2nd and 3rd speeds are for speed reduction drive, 4th speed is for direct drive and 5th speed is for over
drive.
The low speed (1st and 2nd) synchronizer is mounted on middle of the main shaft and engaged with the main shaft
1st or 2nd gear. The high speed (3rd and 4th) synchronizer is mounted on forefront of the main shaft and engaged
with the main shaft 3rd gear or input shaft. The 5th speed synchronizer is mounted on the counter shaft and en-
gaged with the countershaft 5th gear. The 5th speed synchronizer is also equipped with the prevention device from
gear cracking noise when shifting gear into the reverse gear. The double cone synchronizer mechanism is provided
to the 2nd and 3rd gear synchromesh devices for high performance of shifting into the 2nd and 3rd gear.
The gear shift lever case is located at the upper behind the trasmission 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 and cast-iron cases 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 "ON-VEHICLE SERVICE" in this section 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 level/filler plugs
for the oil change or the level check.
For the repair procedure of the transfer unit, refer to Section 7D.