Suzuki Vitara (LY) 2016-2017 · Service Manual D16AA-6M/T Model · Repair Instructions

Gear Shift and Select Shaft Assembly Removal and Installation

Precautions: General safety (00)

Removal
1)Remove battery and tray. icon 
2)Support transaxle using chain hoist or engine crane.
NOTICE:
When lifting engine assembly using chain hoist or the like with engine hook (1), chain or hook may interfere with A/F sensor-1 (2) and EGT sensor-1 (3) including their harnesses and damage them.
Before lifting engine assembly using chain hoist, remove A/F sensor-1 and EGT sensor-1.
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3)Remove engine left mounting, No.1 bracket and No.2 bracket. icon 
4)Disconnect gear shift and gear select control cables from transaxle.
5)Remove gear shift interlock bolt (1).
6)Remove gear shift locating spring (2), if equipped.
7)Remove neutral position switch (3), if equipped.
8)Remove gear shift & select shaft assembly (4) by removing bolts (5).
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Installation
1)Clean mating surfaces of guide case (1) and left case (5), apply sealant to left case as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, and mate guide case with left case.
“A”: Sealant 99000–31260 (SUZUKI Bond No.1217G)
2)Apply sealant to thread of guide case No.2 bolts (2), and then tighten guide case No.1 bolts (4) and guide case No.2 bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond No.1217G)
Tightening torque
Guide case No.1 bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
Guide case No.2 bolt (b): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
3)Apply sealant to thread of gear shift interlock bolt (3), and then tighten gear shift interlock bolt to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond No.1217G)
Tightening torque
Gear shift interlock bolt (c): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
4)Apply sealant to thread of gear shift locating spring (6), and then tighten gear shift locating spring to specified torque, if equipped.
“A”: Sealant 99000–31260 (SUZUKI Bond No.1217G)
Tightening torque
Gear shift locating spring (d): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)
5)Tighten new neutral position switch (7) to specified torque, if equipped.
Tightening torque
Neutral position switch (e): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
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6)Connect gear shift and gear select control cables to transaxle.
7)Install engine left mounting, No.1 bracket and No.2 bracket. icon 
8)Remove chain hoist from engine assembly.
9)Install air cleaner assembly. icon 
10)Check input shaft for rotation in each gear position.