2000 SUZUKI GRAND VITARA ect

YH4
GRAND
VITARA
1. Match mark
7A-12 MANUAL TRANSMISSION (TYPE 1)
REMOUNTING OF TRANS. UNIT
For remounting, reverse dismounting procedure.
Use specified torques as given below.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

For tightening torque of transmission stiffener bolt, refer to
ªENGINE MECHANICALº section.

Set each clamp for wiring, hose and cable securely.

Set clamp for shift control lever boots securely.

After installing clutch operating cylinder, check clutch pedal free
travel. Refer to SECTION 7C1 ªCLUTCHº.

Fill gear oil to transmission and transfer as specified.

Connect battery and check function of engine, clutch and trans.

When installing propeller shaft, align the match marks.

YH4
GRAND
VITARA
MANUAL TRANSMISSION (TYPE 1) 7A-13
1
1. Extension case
2. Select return spring bolt
3. Select return spring (short)
4. Select return spring (long)
5. Guide pin
6. Speed sensor assembly 62,ªAº,(a)
3,ªAº
5,ªAº
5,ªAº
4,ªAº
2,ªAº,(a)
1. Oil seal
2. Extension case
ªBºªAº
1
1
22
EXTENSION CASE (2WD MODEL)
DISASSEMBLY
1) Remove oil seal.
2) Remove select return spring bolts and then springs and guide
pins.
3) Remove speed sensor assembly.
REASSEMBLY
1) Install oil seal.
2) After applying grease, install select guide pins, select return
springs and spring bolts and torque them to specification.
ªAº: Grease 99000-25010
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
After installing, check to make sure that each pin moves smooth-
ly.
3) Install speedometer driven gear case assembly to extension
case.
EXTENSION CASE OIL SEAL (2WD MODEL)
REMOVAL AND INSTALLATION
1) Remove propeller shaft referring to SECTION 4B.
2) Using screwdriver, remove oil seal.
3) Using special tool (A) and plastic hammer, press fit new oil seal
into extension case till oil seal contacts stepped part of extension
case as shown. Be sure to apply grease to oil seal lip.
ªAº: Grease 99000-25010
Special Tool
(A): 09951-16060
4) Clean and inspect sliding portion of propeller shaft front end
(where oil seal contacts) before installation and if even small
dent or scratch exists, correct and clean it again.
Then apply grease inside splines of propeller shaft.
ªBº: Grease 99000-25010
5) Install propeller shaft referring to SECTION 4B.

YH4
GRAND
VITARA
7A-14 MANUAL TRANSMISSION (TYPE 1)
09951-16060
Oil seal installer
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Oil filler / level and drain plugs232.317.0
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back up light switch (Type 1)202.014.5
Back up light switch (Type 2)454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts and nut505.036.5
Exhaust center pipe to manifold nuts505.036.5
Muffler to exhaust center pipe bolts505.036.5
Universal joint flange bolts505.036.5
Select return spring bolts232.317.0
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever.

Select return springs, bolts and guides.
Thread lock cementTHREAD LOCK CEMENT
SUPER 1333B (99000-32020)
Shift control lever locating bolts.
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil Drain and filler / level plugs.
SPECIAL TOOL

YH4
GRAND
VITARA
7A1
MANUAL TRANSMISSION (TYPE 2) 7A1-1
TYPE 2
GENERAL DESCRIPTION7A1-1 . . . . . . . . . . . . . .
DIAGNOSIS7A1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A1-3 . . . . . . . . . . . . . . . .
Gear Oil 7A1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A1-4. . . . . . . . . . . . . . . . . . .
Switches 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A1-4. . . . . . . . . . . . . . . . Dismounting / Remounting of
Trans. Unit 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A1-4 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A1-5 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A1-5 . . . . . .
The manual transmission consists of the input shaft,
main shaft, counter shaft and reverse gear which are
installed in the aluminum and castings cases. Its
gears are of forward five speeds in synchro mesh and
reverse one speed in sliding idler gear arrangement
system.
The main shaft gears are held by the needle bear-
ings and on them the synchronizer rings and syn-
chronizer sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.As the aluminum and castings cases are sealed with
liquid type gasket, it is necessary to use genuine seal-
ant or its equivalent on its mating surfaces when reas-
sembling 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 in-
dependent 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.
SECTION 7A1
MANUAL TRANSMISSION
(TYPE 2)
CONTENTS
GENERAL DESCRIPTION

YH4
GRAND
VITARA
7A1-2 MANUAL TRANSMISSION (TYPE 2)
DIAGNOSIS
ConditionPossible CauseCorrection
Gear slipping out of mesh
Worn shift fork shaft

Worn shift fork or synchronizer sleeve

Weak or damaged locating spring

Worn bearings on input shaft or main shaft

Worn chamfered tooth on sleeve or gear

Missing or disengagement of circlip(s)Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengage
Weakened or broken synchronizer spring

Distorted shift shaft or shift forkReplace
Replace
Hard shifting
Improper clutch pedal free travel

Distorted or broken clutch disc

Damaged clutch pressure plate

Worn synchronizer ring

Worn chamfered tooth on sleeve or gear

Distorted shift shaftAdjust
Replace
Replace clutch cover
Replace
Replace sleeve and gear
Replace
Noise
Inadequate or insufficient lubricant

Damaged or worn bearing(s)

Damaged or worn gear(s)

Damaged or worn synchronizer ring

Damaged or worn chamfered tooth on
sleeve or gearReplenish
Replace
Replace
Replace
Replace

YH4
GRAND
VITARA
Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
7A1-4 MANUAL TRANSMISSION (TYPE 2)
SHIFT CONTROL LEVERS
Refer to SECTION 7A in this manual.
SWITCHES
Refer to SECTION 7A in this manual.
ENGINE REAR MOUNTING
Refer to SECTION 7A in this manual.
DISMOUNTING / REMOUNTING OF TRANS.
UNIT
Refer to the same item in SECTION 7A ªMANUAL TRANSMIS-
SIONº.
For tightening torque of filler and level / drain plug, refer to ªGear Oil
Inspection and Changeº of ªON-VEHICLE SERVICEº in this sec-
tion.
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.

YH4
GRAND
VITARA
7B1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-1
GENERAL DESCRIPTION7B1- 3 . . . . . . . . . . . . . .
CLUTCH / BRAKE FUNCTIONS 7B1- 5. . . . . . . . .
TABLE OF COMPONENT OPERATION 7B1- 6. . .
ELECTRONIC SHIFT CONTROL
SYSTEM 7B1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSIS7B1-17 . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION IN DIAGNOSING
TROUBLE 7B1-20. . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE 7B1-21. . . . . . . . . .
Customer Problem Inspection Form 7B1-23. . .
Malfunction Indicator lamp (MIL)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
ªO / D OFFº Lamp Check 7B1-24. . . . . . . . . . . . .
ªPOWERº Lamp Check 7B1-24. . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Clearance 7B1-24. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) Table7B1-24 . . .
Fail-Safe Table 7B1-25. . . . . . . . . . . . . . . . . . . . .
Visual Inspection 7B1-26. . . . . . . . . . . . . . . . . . .
A / T Basic Check 7B1-27. . . . . . . . . . . . . . . . . . .
Trouble Diagnosis Table 1 7B1-28. . . . . . . . . . .
Trouble Diagnosis Table 2 7B1-28. . . . . . . . . . . Trouble Diagnosis Table 3 7B1-29. . . . . . . . . . .
Scan Tool Data 7B1-30. . . . . . . . . . . . . . . . . . . . .
Inspection of PCM and Its Circuit 7B1-30. . . . .
Wire Harness and Connectors 7B1-30. . . . . . . .
Diagnostic Flow Table A-1 7B1-31. . . . . . . . . . .
Diagnostic Flow Table A-2 7B1-33. . . . . . . . . . .
Table B-1 ªO / D OFFº Light Circuit
Check 7B1-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-2 ªO / D OFFº Light Circuit
Check 7B1-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 ªPOWERº Light Circuit
Check 7B1-37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-4 ªPOWERº Light Circuit
Check 7B1-38. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0705 Transmission Range
Sensor (Switch) Circuit Malfunction 7B1-39. .
DTC P0715 Input / Turbine Speed
Sensor Circuit Malfunction 7B1-42. . . . . . . . . .
DTC P0720 Output Speed Sensor
Circuit Malfunction 7B1-44. . . . . . . . . . . . . . . . .
DTC P0741 TCC Solenoid Valve
Performance or Stuck Off 7B1-46. . . . . . . . . . .
DTC P0743 TCC Solenoid Electrical 7B1-47. .
DTC P0751 Shift Solenoid Valve-A (#1)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
DTC P0756 Shift Solenoid Valve-B (#2)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
SECTION 7B1
AUTOMATIC TRANSMISSION
(4 A
/
T)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS