TSB: SUZUKI AERIO (2002–2007)

Bulletin TSB-05-04289 — May 1, 2009

Bulletin Details

Bulletin IDTSB-05-04289
ManufacturerSUZUKI
ModelsAERIO
Model Years2002–2007
Date IssuedMay 1, 2009
Date Added to NHTSAMay 18, 2009
ComponentPOWER TRAIN:MANUAL TRANSMISSION
Vehicles Affected6 combinations

What is a TSB?

A Technical Service Bulletin is a document issued by the vehicle manufacturer to inform dealership technicians about a known issue and the recommended repair procedure. TSBs are not mandatory recalls — they serve as repair guidance for common problems.

If your vehicle has this issue, bring this bulletin ID to your dealer. If under warranty, the repair should be covered at no cost.

Summary

SUZUKI: PARTS LIST FOR REPAIRING MANUAL TRANSAXLE 5TH GEAR CONCERNS SUCH AS POPPING OUT OF GEAR WHILE DRIVING. WORN OR FAILED 5TH GEAR SYNCHRONIZER, 5TH GEAR, AND RELATED PARTS. *PE

Affected Vehicles

MakeModelYearComponent
SUZUKI AERIO 2007 102000 POWER TRAIN:MANUAL TRANSMISSION
SUZUKI AERIO 2006 102000 POWER TRAIN:MANUAL TRANSMISSION
SUZUKI AERIO 2005 102000 POWER TRAIN:MANUAL TRANSMISSION
SUZUKI AERIO 2004 102000 POWER TRAIN:MANUAL TRANSMISSION
SUZUKI AERIO 2003 102000 POWER TRAIN:MANUAL TRANSMISSION
SUZUKI AERIO 2002 102000 POWER TRAIN:MANUAL TRANSMISSION

Related SUZUKI Recalls

CampaignModelYearComponentSummary
DR-Z400SM 2025 SERVICE BRAKES, HYDRAULIC:CRITICAL FA... Suzuki Motor USA, LLC (Suzuki) is recalling certain 2025-2026 DR-Z400S and 20...
DR-Z400S 2026 SERVICE BRAKES, HYDRAULIC:CRITICAL FA... Suzuki Motor USA, LLC (Suzuki) is recalling certain 2025-2026 DR-Z400S and 20...
DR-Z400S 2025 SERVICE BRAKES, HYDRAULIC:CRITICAL FA... Suzuki Motor USA, LLC (Suzuki) is recalling certain 2025-2026 DR-Z400S and 20...
DL1050 2021 EXTERIOR LIGHTING:HEADLIGHTS Suzuki Motor USA, LLC (Suzuki) is recalling certain 2020-2025 DL 1050 and 202...
GSX-S1000S 2024 EXTERIOR LIGHTING:HEADLIGHTS Suzuki Motor USA, LLC (Suzuki) is recalling certain 2020-2025 DL 1050 and 202...

What Should You Do?

If your vehicle is affected by this TSB, contact your authorized SUZUKI dealer. Bring this bulletin ID (TSB-05-04289) when you visit. If under warranty, the repair should be free. If your warranty has expired, ask about goodwill coverage — manufacturers sometimes cover TSB-related repairs beyond the warranty period.

Frequently Asked Questions

A recall is a mandatory safety fix — the manufacturer must repair every affected vehicle for free. A TSB is an advisory document that describes a known issue and the recommended fix, but repairs are not required. However, some TSBs eventually lead to recalls if the issue poses a safety risk. TSBs are generally issued for quality or performance problems, while recalls address safety defects.

If your vehicle is still under the manufacturer's warranty, TSB-related repairs are typically covered at no cost. If your warranty has expired, you can ask the dealer about goodwill or customer assistance programs. Many manufacturers will cover or partially cover repairs for well-known issues, especially if the TSB was issued recently or affects a large number of vehicles.

Check the make, model, and model year listed above against your vehicle. If they match, this bulletin likely applies. However, TSBs may only affect vehicles with specific production dates, VIN ranges, or configurations. Your dealer can confirm by entering your VIN into their service system, which will show all applicable TSBs and recalls.

This data comes from the National Highway Traffic Safety Administration (NHTSA). Manufacturers are required to submit copies of all communications (including TSBs) sent to their dealers to NHTSA. The agency makes this data publicly available as part of its vehicle safety monitoring program.