Manual Transmission/Transaxle; Manual Transmission Construction - Suzuki GRAND VITARA 2005 Service Manual

5B-1 Manual Transmission/Transaxle:

Manual Transmission/Transaxle

Manual Transmission Construction

The manual transmission consists of the input shaft, main 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 and 3rd speeds are for speed reduction drive, 4th speed is for direct drive 5th speed is for speed
increasing drive. The low speed (1st and 2nd) synchronizer is mounted on the main shaft and engaged with the main
shaft 1st or 2nd gear. The high speed (3rd and 4th) synchronizer is mounted on of the main shaft and engaged with
the main shaft 3rd gear or input shaft 4th gear. The 5th & reverse synchronizer is mounted on the main shaft and
engaged with the main shaft 5th or reverse gear. 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.
The double cone synchronizing mechanism is provided to 1st gear synchromesh. The triple cone synchronizing
mechanism is provided to 2nd and 3rd gear synchromesh.
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. Input shaft
2. Transmission front case
3. Input shaft bearing retainer
4. 4th gear
5. High speed synchronizer hub
General Description
6. 3rd gear
7. 2nd gear
8. Low speed synchronizer hub
9. 1st gear
10. Reverse gear
11. 5th & reverse synchronizer hub
12. Main shaft
13. Reverse shift shaft
14. Adapter case
15. Countershaft
S5JB0B5201001
I5JB0B520001-01
16. Rear case
17. Reverse idle gear
18. Reverse idle gear shaft
19. Reverse idle gear case