Suzuki Vitara, Grand Vitara, XL7 2000-06

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Drain the transfer case fluid, if equipped.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Shift lever boots
     
    Gear shift lever
     
    Transfer case shift lever, if equipped
     
    4WD switch connector, if equipped
     
    Reverse light switch connector
     
    Starter motor
     
    Front driveshaft, if equipped
     
    Rear driveshaft
     
    Speedometer cable, if equipped
     
    Vehicle Speed (VSS) sensor, if equipped
     
    Clutch slave cylinder or cable
     
    Flywheel access cover
     
    Transmission flange bolts and nuts
     
    Transmission braces, if equipped
     

  8.  
  9. Support the transmission with a jack and remove the transmission mount and crossmember.
  10.  
  11. Place a wooden block at the rear of the cylinder head as shown to support the engine when the transmission is removed.

    Click image to see an enlarged view

    Fig. Support the engine with a wooden block between the cylinder head and the firewall-All models

  12.  
  13. Lower the transmission away from the vehicle.
  14.  

To install:

  1. Install or connect the following:

    Transmission. Tighten the flange fasteners to 62-72 ft. lbs. (85-98 Nm).
     
    Transmission mount and crossmember. Tighten the fasteners to 29-43 ft. lbs. (40-60 Nm).
     
    Transmission braces, if equipped. Tighten the bolts to 62-72 ft. lbs. (85-98 Nm).
     
    Flywheel access cover
     
    Clutch slave cylinder or cable
     
    VSS sensor, if equipped
     
    Speedometer cable, if equipped
     
    Rear driveshaft
     
    Front driveshaft, if equipped
     
    Starter motor
     
    Reverse light switch connector
     
    4WD switch connector, if equipped
     
    Transfer case shift lever, if equipped
     
    Gear shift lever
     
    Shift lever boots
     
    Negative battery cable
     

  2.  
  3. Fill the transmission to the correct level.
  4.  
  5. Fill the transfer case, if equipped.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Drain the transfer case fluid, if equipped.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Shift lever boots
     
    Gear shift lever
     
    Transfer case shift lever, if equipped
     
    4WD switch connector, if equipped
     
    Reverse light switch connector
     
    Starter motor
     
    Front driveshaft, if equipped
     
    Rear driveshaft
     
    Speedometer cable, if equipped
     
    Vehicle Speed (VSS) sensor, if equipped
     
    Clutch slave cylinder or cable
     
    Flywheel access cover
     
    Transmission flange bolts and nuts
     
    Transmission braces, if equipped
     

  8.  
  9. Support the transmission with a jack and remove the transmission mount and crossmember.
  10.  
  11. Place a wooden block at the rear of the cylinder head as shown to support the engine when the transmission is removed.

    Click image to see an enlarged view

    Fig. Support the engine with a wooden block between the cylinder head and the firewall-All models

  12.  
  13. Lower the transmission away from the vehicle.
  14.  

To install:

  1. Install or connect the following:

    Transmission. Tighten the flange fasteners to 62-72 ft. lbs. (85-98 Nm).
     
    Transmission mount and crossmember. Tighten the fasteners to 29-43 ft. lbs. (40-60 Nm).
     
    Transmission braces, if equipped. Tighten the bolts to 62-72 ft. lbs. (85-98 Nm).
     
    Flywheel access cover
     
    Clutch slave cylinder or cable
     
    VSS sensor, if equipped
     
    Speedometer cable, if equipped
     
    Rear driveshaft
     
    Front driveshaft, if equipped
     
    Starter motor
     
    Reverse light switch connector
     
    4WD switch connector, if equipped
     
    Transfer case shift lever, if equipped
     
    Gear shift lever
     
    Shift lever boots
     
    Negative battery cable
     

  2.  
  3. Fill the transmission to the correct level.
  4.  
  5. Fill the transfer case, if equipped.
  6.  

 
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