1987 SUZUKI GRAND VITARA Service Repair Manual

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

10) Remove low gear bush, low speed synchro-
nizer hub, ring, spring, 2nd gear and 2nd
gear bearing by using hydraulic press.
Hydraulic press
Bush
Fig. 13-20
Removing Shift Yokes, Forks and Shafts
412 3 2712 8?
1.
2.
3.
4.
5.
6. 7. Reverse gear shift shaft
8.
Reverse gear shift rim yoke 12.
High speed gear shift shaft
9.
Reverse gear shift fork Low speed gear shift shaft
13.
10.
Low speed gear shift yoke 11.
5th gear shift yoke Low speed gear shift fork
Shift yoke pin High speed gear shift fork
5th select return spring Reverse gear shift rim
spring
E-ring
14.
Fig. 13-21
[Gear shift yokel
For shift yoke removal, drive out yoke pin with
spring pin remover (special tool) first, and then
remove yoke.
Spring pin remover (C) (09922-85811)
Fig. 13-22
[Gear shift fork and shaft]
Before starting removal, make sure that all
shift fork shafts in place are in neutral position and remove each fork and shaft according to
following 1), 2) and 3).
Fig. 13-23 Neutral position1) Pull out reverse gear shift shaft. As this shaft comes out, locating ball and spring
will jump out of hole; do not let them
fly away.
13-10
Fig, 13-24

2) Using the same special tool (C), mentioned
above, drive out yoke pin on high speed
gear shift fork, and pull out shift shaft.
As in above case, be careful not to let
locating ball, interlock ball and spring fly
away.
1 CAUTION:
3) Drive yoke pin out of low speed gear shift
fork as in above step 2) and pull out fork
shaft and fork.
When removing yoke pin, be sure not to
drive it out so far as to contact case. Or it
will cause damage to case.
Fig. 13-27
Fig. 13-25
Fig. 13-28
Fig. 13-26
13-11