1987 SUZUKI GRAND VITARA Service Repair Manual

12-1. GENERAL DESCRIPTION
In this gear shifting control system, by its mechanical structure, the movement of the gear shift lever,
which is located beside the driver’s seat, directly actuates the gear shift fork shaft to shift the gear into the
selected position. This system consists of the following parts.
I.2.
3.4.
5.6.7.
8.9.
10.11.
12.
13.14.
15.
16.17.
18.
19.
Gear shift lever knobGear shift leverGear shift lever boot No. 2
Gear shift lever boot No. 1Gear shift lever case coverGear shift lever locating bolt
Gear shift lever caseReverse select pin screwReverse select locating springs
Reverse select locating ball
Reverse select guide pinReverse gear shift fork shaft
High speed gear shift fork shaft
Select return springs
Low speed select pin bolt
Low speed select guide pin
Low speed gear shift fork shaft
Gear shift lever wave washer
Gear shift lever seat1
Fig. 12- 1
12-2

12-2. REMOVAL
Gear Shift Lever
1) Remove bolts tightening gear shift lever boot
No. 2 and take boot off floor center tunnel.
Fig. 12-2
2) Take boot No. 1 off gear shift lever case and
move it up (toward knob).
3) Remove 3 bolts tightening gear shift lever case
cover.
Fig. 12-3
4) Pull gear shift lever out of gear shift lever case.
Fig. 12-4
Gear Shift Lever Select Guide Pins
1) After gear shift lever is removed according
to foregoing steps 1) through 4), remove gear
shift lever case by loosening its tightening
bolts.
Fig. 12-5
2) Remove reverse select pin screw and take out
spring and ball from case.
3) Remove low speed select pin bolt.
4) Compress reverse select guide pin @ against
low speed select guide pin @ and take it out
of gear shift lever case.
Compress
Fig. 12-6
Removal
12-3

12-3. INSPECTION OF COMPONENTS
Gear Shift Lever
Check lower end of gear shift lever where gear
shift fork shaft contact, @ and 0, for wear
and any kind of damage. Worn or damaged gear
shift lever must be replaced with a new one.
Fig. 12-7
Reverse & Low Speed Select Guide Pins
Check both select guide pins where gear shift
lever contacts, 0, for stepped wear. Replace
worn select guide pin.
Move shaft and check low speed select guide
pin for smooth movement without rattle. If
found defective, replace it and apply grease to
pin.
Fig. 12-9
Gear Shift Fork Shaft
Visually check each gear shift fork shaft (High,
Low and Reverse) where gear shift lever contacts,
@, for wear. Worn shaft must be replaced.
I
0
0
Fig. 12-10
Fig. 12-8
12-4

12-4. INSTALLATION
Gear shift lever is installed by reversing removal
procedure. Some important steps will be explain-
ed in detail.
NOTE:
After each guide pin is installed, make sure that
flat surfaca @I at the tip of pin faces upward
(toward gear shift lever).
Reverse & Low Speed Guide Pins
Be sure to apply grease to select guide pins
before installing them into gear shift lever case.
Fig. 12- 11
When fitting low speed select guide pin into
gear shift lever case, tighten locating bolt while
pushing pin so that bolt goes in the groove
provided in the pin. Then install reverse select
guide pin in case and securely fit the locating
balkin the groove provided in the pin.
Fig. 12-13
Gear Shift Lever Case
When installing lever case to transmission
extension case, clean joint faces, and then apply
sealant (SUZUKI BOND NO. 1215, 99009
31110) to joint faces.
Fig. 12- 14
Fig. 12- 12
12-5

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