Full Service Manual Vitara 1998-2005 (Transmission Service Manual)

Manual List	file://../ManualList.pdf#page=1IMPORTANT
	WARNING/CAUTION/NOTE
FOREWORD
TABLE OF CONTENTS
SECTION 7A
	GENERAL DESCRIPTION
		COMPONENTS
	UNIT DISASSEMBLY
		GEAR SHIFT LEVER CASE (4WD MODEL)
		GEAR SHIFT LEVER CASE (2WD MODEL)
		TRANSMISSION UNIT
		SUB-ASSEMBLY
			INPUT SHAFT
			MAIN SHAFT
			UPPER CASE AND SHIFTER
	COMPONENT INSPECTION
		COUNTER SHAFT AND MAIN SHAFT INNER PARTS
			LOW AND REVERSE SCISSORS GEAR ASSEMBLIES (IF EQUIPPED)
		UPPER CASE AND SHIFTER
		REAR CASE
	UNIT ASSEMBLY
		GEAR SHIFT LEVER CASE (4WD MODEL)
		GEAR SHIFT LEVER CASE (2WD MODEL)
		SUB ASSEMBLY
			MAIN SHAFT
			COUNTER SHAFT
			UPPER CASE AND SHIFTER
		TRANSMISSION UNIT
	TIGHTENING TORQUE SPECIFICATION
	REQUIRED SERVICE MATERIAL
	SPECIAL TOOL
SECTION 7A1
	GENERAL DESCRIPTION
		COMPONENTS
	UNIT DISASSEMBLY
		GEAR SHIFT LEVER CASE
		TRANSMISSION UNIT
		SUB-ASSEMBLY
			INPUT SHAFT ASSEMBLY
			MAIN SHAFT ASSEMBLY
			COUNTER SHAFT & REVERSE IDLE GEAR
			INPUT SHAFT BEARING RETAINER AND OIL SEAL
			TRANSMISSION REAR CASE
	COMPONENTS INSPECTION
		SUB-ASSEMBLY
			INPUT SHAFT ASSEMBLY
			MAIN SHAFT ASSEMBLY
			COUNTER SHAFT AND REVERSE IDLE GEAR
	UNIT ASSEMBLY
		GEAR SHIFT LEVER CASE
		SUB-ASSEMBLY
			INPUT SHAFT ASSEMBLY
			MAIN SHAFT ASSEMBLY
			COUNTER SHAFT AND REVERSE IDLE GEAR
			INPUT SHAFT BEARING RETAINER AND OIL SEAL
			TRANSIMISSION REAR CASE
			TRANSMISSION INTERMEDIATE CASE AND FRONT CASE (LOCATION OF KNOCK AND PLUG)
		TRANSMISSION UNIT
	TIGHTENING TORQUE SPECIFICATION
	REQUIRED SERVICE MATERIAL
	SPECIAL TOOL
SECTION 7B1
	GENERAL DESCRIPTION
	TORQUE CONVERTER DIAGNOSIS
		STATOR ASSEMBLY FREEWHEELS
		STATOR ASSEMBLY REMAINS LOCKED UP
		DO NOT REPLACE CONVERTER FOR FOLLOWING CONDITIONS :
	UNIT REPAIR
		PRECAUTIONS
		PART INSPECTION AND CORRECTION TABLE
		UNIT DISASSEMBLY
		SUB-ASSEMBLY REPAIR
			OIL PUMP
			OVERDRIVE (PLANETARY GEAR SIDE)
			OVERDRIVE (CASE SIDE)
			FORWARD CLUTCH
			DIRECT CLUTCH
			CENTER SUPPORT
			PLANETARY GEARS AND OUTPUT SHAFT
			VALVE BODY ASSEMBLY
			FRONT UPPER VALVE BODY
			REAR UPPER VALVE BODY
		UNIT ASSEMBLY
			BEARING AND RACE INSTALLATION DIAGRAM
	TIGHTENING TORQUE SPECIFICATION
	REQUIRED SERVICE MATERIAL
	SPECIAL TOOL
SECTION 7D
	GENERAL DESCRIPTION
		COMPONENTS
	UNIT REPAIR
		DISASSEMBLY
		COMPONENT INSPECTION
		ASSEMBLY
	TIGHTENING TORQUE SPECIFICATION
	REQUIRED SERVICE MATERIAL
	SPECIAL TOOL
SECTION 7E
	GENERAL DESCRIPTION
		COMPONENT
	UNIT REPAIR
		DISASSEMBLY UNIT
		COMPONENTS INSPECTION
			DIFFERENTIAL LEFT CASE
			FREE AXLE HUB
			ACTUATOR
		SUBASSEMBLY ADJUSTMENT AND REASSEMBLY
			DIFFERENTIAL CARRIER
			DIFFERENTIAL CASE
			DRIVE BEVEL PINION
		ASSEMBLY UNIT
	TIGHTENING TORQUE SPECIFICATION
	REQUIRED SERVICE MATERIAL
	SPECIAL TOOL
SECTION 7F
	GENERAL DESCRIPTION
	UNIT REPAIR
		DISASSEMBLING UNIT
		COMPONENT INSPECTION
		SUB-ASSEMBLY ADJUSTMENT AND REASSEMBLY
			DIFFERENTIAL CARRIER
			DIFFERENTIAL CASE
			DIFFERENTIAL SIDE BEARING
			DRIVE BEVEL PINION
		ASSEMBLING UNIT
	TIGHTENING TORQUE SPECIFICATION
	REQUIRED SERVICE MATERIAL
	SPECIAL TOOL