SUZUKI GRAND VITARA 1987 Service Repair Manual

Gear Shift Control Lever Seat
Make sure to fit control lever seat @I into
gear shift lever case so that locating bolt @
goes in the groove of control lever seat. And
fit wave washer @J with its projection surface
directed upward.
--
Fig. 12-15
Tightening Torque (h Greasing point
To be tightened to:N-mkg-mlb-ft
(jj Lever case cover
bolt4 - 70.4 -0.73.0- 5.0
0Reverse selectpin screw25 - 352.5 - 3.518.5 - 25.0
0Lever bootbolt4- 70.4- 0.73.0- 5.0
@Lever locatingbolt14-201.4-2.010.5- 14.0
0Lever case ’bolt18-281.8-2.813.5-20.0
a Low speed
select pin bolt4-70.4 - 0.73.0 - 5.0
APPLY to
@ :Between gear shift lever boot No. 1 and lever
case cover
@:Between gear shift lever and lever seat
Between gear shift lever and lever case
Gear shift lever locating bolt
* Grease to be used for each greasing point is
SUZUKI SUPER GREASE A(99000-25010).
* If gear shift lever locating bolt is removed
from case, be sure to apply locking agent
(THREAD LOCK CEMENT SUPER “1333B”
99000-32020) to bolt thread for reinstalla-
tion.
Fig. 12-16
12-6

SECTION 13
TRANSMISSION
CONTENTS
13-l. GENERAL DESCRIPTION..................................13-1
TRANSMISSION GEAR RATIO..............................13-3
13-3. DISMOUNTING...........................................13-4
DISASSEMBLY............................................13-5
13-5. INSPECTION OF COMPONENTS............................13-12
13-6. IMPORTANT STEPS IN INSTALLATION.....................13-15
13-7. MAINTENANCE SERVICES................................13-25
13-8. RECOMMENDED TORQUE SPECIFICATION.................. 13-26
13-1. GENERAL DESCRIPTION
241.Main shaft rear bearing
2. 5th gear washer
3. Main shaft washer bell
4. 5th gear needle bearing
Oil sealfiMain shi5.5thgear
6.ICirclip
7. Synchronizer reverse hub set
8.Synchronizer key
9.Synchronizerspring
10.Gear bush
11.Needle bearing
12.Reversegear
13. Main shaft bearing washer
14. Main shaft bearing15.C ring
16.Lowgear
17.Synchronizer low speed hub set
18.Synchronizerkey
19.Synchronizerspring
20.2ndgear
F21. 3rd gear needle bearing22.3rdgear
23.hub
I
1High speed synchronizerset
I
24. Input shaft bearing25.Input shaft
i ’
IL’
ear bearing26. C ring27.AFront bearing
28.Counter shaft
429.Center bearing
930.ReversegearI i31. Counter shaft 5th gear
932.Pin
33.Washer
34. Reverse idle gear
35. Reverse gear shaft
13-1
13-2.
13-4.
13

3rd gear
Low soeed qear. -shift forkHigh speed gear shift fork
Reduction drive gear
2ndqsarLow gear Tar
Input shaft\ -ha-A
Counter shaft
Spking
Fig. 13-2
13-2

Reverse gear shift fork
Reverse gear
Ii
5th gear
I
Counter shaft 5th gaar
Counter shaft reverse gear
r
Reverse idle gear
13-2. TRANSMISSION GEAR RATIO
Primary gear ratio35123-
IPrimary speed ratio
Gear ratio
Secondary ratios
Speed ratio
Overall speed reduction ratio
41/18
2.277
3.466
-1.521
LowSecondThirdFourthFifth
36/l53212529131-25144
2.4001.2800.935-0.568
3.6521.9471.4231.0000.864
13-3

13-3. DISMOUNTINGIn Passenger Compartment
1) Loosen 4 bolts fastening gear shift lever boot
No. 2 and move boot upward.
Fig.
13-2- 1 Under Engine
7) Remove drain plug to drain oil in transmis-
sion.
8) Disconnect clutch wire from clutch release
lever.
9) Remove propeller shaft No. 1 (from trans-
mission to transfer).
10) Remove propeller shaft No. 2 (from transfer
to front differential).
11) Remove clutch housing lower plate from
transmission case.
2) Move gear shift boot No. 1 upward. Loosen
gear shift lever case cover bolts (3
PCS) and
draw gear shift lever out of lever case.
Fig. 13-2-3
Fig. 13-2-2 In Engine Room
3) Disconnect negative (-) and positive (+)
cords from battery terminals.
4) Disconnect back light and fifth switch lead
wires at coupler respectively.
5) Disconnect Black/Yellow lead wire and posi- tive
(+) cord from starter motor.
6) Remove starter motor from transmission
case and fuel hoses clamp from transmission
case.
12) Remove bolts and nuts fastening engine
cylinder block and transmission case.
13) Remove pipe (iJ as shown in Fig. 13-24.
Fig. 13-2-4
14) Remove exhaust center pipe.
15) Remove transmission rear mounting bracket
from chassis and transmission case.
NOTE:
Before starting to remove transmission, check
around once again to be sure that there is no
connection left undone.
16) Take down transmission.
13-4

13-4. DISASSEMBLY
Replacing Clutch Release Shaft Bush
1) Remove clutch release bearing from input
shaft bearing retainer.
Fig. 13-3-Z
4) Take out the other bush, too.
Fig. 13-3
2) Remove a part of spring from clutch release
shaft lever.
Fig. 13-3-3
Fig. 13-3- 1
3) Remove clutch release shaft spring from
shaft. With special tool (A) applied in such a
position as shown in Fig. 13-3-2, tap the end
of special tool to take out bush and cap.
Clutch release bush remover (A) (09925
48210)
5) Precautions on bush reinstallation:
l Make sure to apply grease to inside of bushes.
l Drive in bushes to the same level as inside
surface of transmission case. Install cap and
oil seal securely after greasing oil seal lip.
Fig. 13-3-4
13-5

Fig. 13-3-5
l After installing seal, caulk transmission case
against seal at two points.
Separating Upper Case from Lower Case
1) Remove clutch release bearing from trans-
mission input shaft.
Fig. 13-4-2
4) Remove bolts fastening upper and lower
cases together, separate the two, and take
out main shaft assembly. A steel bar, similar
in shape to screwdriver, may have to be
used to pry two cases apart, as shown. In
such a case, do not stick bar too far into
between two mating faces, or faces may
become damaged.
Fig. 13-4
2) Remove input shaft bearing retainer bolts
and pull out retainer by using 3 conventio-
nal 6 mm bolts.
Fig. 13-5
Fig. 13-4-l
3) Remove bolts securing extension
transmission case and reverse shift
0. Then take off extension case.
13-6
case to
rim bolt
Fig. 13-5 1

3) Remove counter-shaft 5th gear and counter-
shaft reverse gear.
Fig. 13-5-2
Removing Countershaft
1) Remove reverse gear shaft with gear.
Fig. 13-8
Fig. 13-6
2) Remove countershaft rear bearing.
Bearing puller (B) (09913-65135)
Fig. 13-7
4) Remove circlip from countershaft. Push
out countershaft to extension case side by
using hydraulic press, remove bearing, and
take countershaft assembly out of case.
Bearing puller (B) (09913-65135)
Fig. 13-9
Fig. 13-9-l
13-7

Removing Main Shaft and Input Shaft
l)Take out input shaft by hand, taking care
not to let high-speed synchronizer ring fall
off.
-
Fig. 13-12
Bearing puller
(B)(09913-65135)
Fig.
13-10
2) Remove circlip retaining hub of high-speed
synchronizer sleeve, and slide off sleeve
hub, third driven gear and needle bearing
from main shaft.
Fig. 13-13
Fig.
13-l 1
3) Remove circlip retaining rear bearing on
main shaft. Remove main shaft bearing.
4) From main shaft, take off 5th gear washer,
ball, 5th gear, 5th speed synchronizer ring
and 5th gear needle bearing,
Fig. 13-14
13-8

5) Remove circlip retaining the reverse synchro-
nizer hub on main shaft.
Fig. 13-15
6) Remove reverse synchronizer hub, reverse
gear and reverse gear needle bearing.
Hydraulic press
Bush
Fig. 13-17
8) Remove ball and main shaft (center) bearing
by using hydraulic press.
NOTE:
In the state as shown below, there is a ball in
washer which is located under bearing. Be sure
to prevent it from falling off and getting lost.
Hydraulic press
Fig. 13-16
Fig. 13-18
7) Remove bearing washer and reverse gear
bush on main shaft by using hydraulic press.
NOTE:
During this removal, watch out for a ball which
may fall off. It must not be lost. Also, ball
bearing should not be removed together with
above washer and bush.
9) Remove low gear, needle bearing, synchro-
nizer ring and spring on main shaft.
Fig. 13-19
13-9