5A
Automatic Transmission Unit Disassembly and Reassembly
Reference: Automatic Transmission Unit Dismounting and Remounting
Disassembly
1) Remove torque converter (1).
2) Remove input shaft speed sensor (2).
3) Remove input shaft speed sensor (3).
4) Remove fluid cooler pipe bolts (1) and union bolts (2), and then remove fluid cooler pipes (3) and washers (4).
5) Remove manual selector lever (1).
6) Uncaulk lock washer (2), and then remove lock nut (3) and lock washer (2).
7) Remove transmission range sensor (4).
8) Remove 8 bolts (1), and then remove rear extension case (2).
9) Remove oil seal (1) from extension case (2).
10) Remove output shaft bearing (1).
11) Remove oil filler tube (1).
12) Remove 19 oil pan bolts (1), and then remove oil pan (2) and gasket (3).
13) Remove magnets (1) from oil pan (2).
14) Remove oil strainer (1) and O-ring (2) from valve body.
15) Remove transmission fluid temperature sensor (1) from clamp.
16) Disconnect solenoid connectors (2).
17) Remove valve body harness connector (3) from transmission case.
18) Remove 18 bolts (1), then remove valve body assembly (2).
19) Remove O-ring (1) and brake drum gasket (2).
20) Remove accumulator pistons and accumulator springs of forward clutch (1), direct clutch (2), reverse clutch (3), O/D and 2nd coast brake (4) and 2nd brake (5).
21) Remove parking lock pawl bracket (1).
22) Remove manual shift lever spring (1).
23) Turn manual shift lever (1) in arrow direction, and then remove parking lock rod (2).
24) Pull out parking lock pawl shaft (1) in arrow direction, and then remove spring (2) and parking lock pawl (3).
25) Uncaulk spacer (1), turn it in arrow direction, and then remove spring pin (2) using special tool.
Special Tool
(A) : 09922–89810
26) Pull out manual shift lever shaft (1), and then remove manual shift lever (2) and spacer (3).
27) Remove 2 oil seals (1).
28) Remove torque converter housing (1).
29) Remove torque converter housing (1) while tapping around it lightly with plastic hammer.
30) Using special tools, remove oil pump assembly (1) and gasket (2).
Special Tool
(A) : 09920–13120
(B) : 09927–66520
31) Remove thrust washer (1) and reverse clutch assembly (2).
32) Remove bearing (1) and forward clutch & input shaft assembly (2).
33) Remove 2 bearing races (1), bearing (2) and forward clutch hub (3).
34) Remove bearing (1), bearing race (2), front sun gear (3) and thrust washer (4).
35) After removing snap ring (1), remove O/D and 2nd coast brake separator plate (2), friction plates (3) and friction discs (4).
36) Using special tools, compress O/D and 2nd coast brake piston return spring (1) and remove snap ring (2).
Special Tool
(A) : 09920–13120
(B) : 09925–86010
(C) : 09927–66510
37) Remove O/D and 2nd coast brake piston return spring seat (3), O/D and 2nd coast brake piston return spring (4) and O/D and 2nd coast brake piston assembly (5).
38) Remove one-way clutch No.1 (1).
39) After removing snap ring (1), remove 2nd brake separator plate (2), friction discs (3) and friction plates (4).
40) Remove 2nd brake apply tube (1).
41) After removing snap ring (1), remove bearing, (2) rear sun gear (3), bearing race (4), one-way clutch No.2 (5), 2nd brake piston assembly (6), thrust washer (7) and planetary gear assembly (8).
42) After removing snap ring (1), remove 1st & reverse brake separator plate (2), friction discs (3), friction plates (4) and retaining plate (5).
43) Remove direct clutch & output shaft assembly (1).
44) Remove bearing race (1), bearing (2) and 1st & reverse brake apply tube (3).
45) Using special tool, compress 1st & reverse brake piston return spring (1), and then remove snap ring (2).
Special Tool
(A) : 09922–86010
46) Remove 1st & reverse brake piston return spring (1).
47) Blow air into oil hole (1) as shown in figure, remove 1st & reverse brake piston (2).
Reassembly
1) After applying A/T fluid to new O-rings, install them to 1st & reverse brake piston (1).
2) Install 1st & reverse brake piston (1) to transmission case.
NOTE:
Be careful not to damage O-ring when installing 1st & reverse brake piston.
3) Install 1st & reverse brake piston return spring (1).
4) Using special tool, compress 1st & reverse brake piston return spring (1), and then install new snap ring (2).
Special Tool
(A) : 09922–86010
5) Make sure that 1st & reverse brake piston (1) move smoothly when blowing and not blowing low pressure compressed air into oil hole (2) of transmission case.
6) Install 1st & reverse brake apply tube (1).
NOTE:
Make sure that tab (2) of 1st & reverse brake apply tube fits into notch (3) of transmission case.
7) Check pack clearance of 1st & reverse brake referring to 1st & Reverse Brake Inspection .
NOTE:
Perform pack clearance check before installing direct clutch & output shaft assembly.
8) Install bearing (1) and bearing race (2).
9) Install direct clutch & output shaft assembly (1).
10) Install planetary gear assembly (1), thrust washer (2), bearing race (3), rear sun gear (4) and bearing (5).
NOTE:
Align projection (6) of thrust washer with hole (7) in planetary gear assembly.
11) Install 1st & reverse brake disc set (retaining plate (1), 4 friction discs (2), 3 friction plates (3) and separator plate (4)), then install snap ring (5).
12) Install 2nd brake piston assembly (1).
NOTE:
Align projection (2) of 2nd brake piston assembly (1) and recess (3) of transmission case.
13) Install one-way clutch No.2 (1), then install snap ring (2).
NOTE:
Do not align projection (3) of one-way clutch No.2 and recess (4) of transmission case.
14) Turn planetary gear assembly (1) to check that planetary gear assembly moves smoothly when turned clockwise and planetary gear assembly locks when turned counterclockwise.
NOTE:
When planetary gear assembly (1) turns counterclockwise, check if one-way clutch No. 2 (2) is installed properly.
15) Install 2nd brake apply tube (1).
16) Install 2nd brake disc set (3 friction plates (1), 3 friction discs (2) and separator plate (3)), then install snap ring (4).
17) Check pack clearance of 2nd brake referring to O/D and 2nd Coast Brake Inspection .
18) Install one-way clutch No.1 (1).
19) Install front sun gear (1) to one-way clutch No.1 (2) and check that front sun gear (1) moves smoothly when turned clockwise and front sun gear locks when turned counterclockwise.
NOTE:
When front sun gear turns counterclockwise, check if one-way clutch No. 1 (2) is installed properly.
20) Remove front sun gear.
21) Install O/D and 2nd coast brake piston assembly (1), O/D and 2nd coast brake piston return spring (2) and O/D and 2nd coast brake piston return spring seat (3).
22) Using special tools, compress O/D and 2nd coast brake piston return spring (2) and install snap ring (4).
Special Tool
(A) : 09920–13120
(B) : 09925–86010
(C) : 09927–66510
23) Check pack clearance of O/D and 2nd coast brake referring to O/D and 2nd Coast Brake Inspection .
24) Install thrust washer (1), front sun gear (2), bearing race (3) and bearing (4).
NOTE:
Align projection (5) of thrust washer and holes (6) in front sun gear.
25) Install O/D and 2nd coast brake disc set (2 friction plates (1), 2 friction discs (2) and separator plate (3)), then install snap ring (4).
26) Install forward clutch hub (1), 2 bearing races (2) and bearing (3).
27) Install forward clutch & input shaft assembly (1) and bearing (2).
28) Check for correct installation of forward clutch & input shaft assembly (1) as follows.
Measure distance “a” by using micrometer caliper (2) and straightedge (3). If out of specification, remove forward clutch & input shaft assembly, forward clutch hub and reinstall them properly.
Distance between forward clutch & input shaft assembly and mating surface of transmission case
“a”: 45.83 – 46.79 mm (1.804 – 1.842 in.)
29) Install reverse clutch assembly (1).
30) Check for correct installation of reverse clutch assembly (1) as follows.
Measure distance “a” by using micrometer caliper (2) and straightedge (3). If out of specification, remove reverse clutch assembly, reverse and reinstall it properly.
Distance between reverse clutch assembly and mating surface of transmission case
“a”: 25.21 – 26.27 mm (0.993 – 1.034 in.)
31) Fit thrust washer (1) to oil pump assembly (2) with petroleum jelly so that washer does not fall off when assembling A/T unit.
NOTE:
Align projection of thrust washer and recess of oil pump assembly.
32) Install new gasket (1) and oil pump assembly (2), then tighten 7 bolts to specified torque.
Tightening torque
Oil pump bolt ( a ): 12 N·m ( 1.2 kg-m, 9.0 lb-ft)
33) Blow air into forward clutch (1), reverse clutch (2), O/D and 2nd coast brake (3), 2nd brake (4), direct clutch (5) and 1st & reverse brake (6) oil passage shown in figure blow and check each piston for operation sound.
NOTE:
When no operation sound is heard, disassemble and check each component for proper installation.
34) Apply sealant to torque converter housing (1) over transmission case installation surface, install converter housing (1) in transmission case and tighten 10 bolts to specified torque.
Tightening torque
Torque converter housing bolt ( a ): 25 N·m ( 2.5 kg-m, 18.0 lb-ft)
“A” : Sealant 99000–31230 ( SUZUKI Bond No.1216B )
35) Using special tool, install 2 oil seals (1).
NOTE:
Use new oil seals and apply grease to their lip.
Special Tool
(A) : 09925–98210
: Grease 99000–25010 ( SUZUKI Super Grease A )
36) Install manual shift lever shaft (1), new spacer (2) and manual shift lever (3).
37) Using special tool, drive in new spring pin (1).
Special Tool
(A) : 09922–89810
38) Turn spacer in arrow direction to caulk it.
39) Install parking lock pawl (1), parking lock pawl shaft (2) and spring (3).
40) Install parking lock rod (1) to manual shift lever (2).
41) Install manual shift lever spring (1) and tighten bolt to specified torque.
Tightening torque
Manual shift lever spring bolt ( a ): 15 N·m ( 1.5 kg-m, 11.0 lb-ft)
42) Install parking lock pawl bracket (1) and tighten 3 bolts to specified torque.
Tightening torque
Parking lock pawl bracket bolt ( a ): 8 N·m ( 0.8 kg-m, 6.0 lb-ft)
43) Install accumulator pistons and accumulator springs (6) of forward clutch (1), direct clutch (2), reverse clutch (3), O/D and 2nd coast brake (4) and 2nd brake (5) to automatic transmission case.
NOTE:
Use new O-ring for each accumulator piston and apply A/T fluid to it.
Accumulator spring identification
Accumulator piston Accumulator spring
Free length “a” Color
Forward clutch 51.9 mm (2.0433 in.) Blue
Direct clutch 67.4 mm (2.6535 in.) Yellow
Reverse clutch 61.4 mm (2.4173 in.) Purple
O/D and 2nd coast brake 45.4 mm (1.7874 in.) Light Blue
57.7 mm (2.2716 in.) Light Blue
2nd brake 47.8 mm (1.8819 in.) Yellow
66.9 mm (2.6339 in.) Light Green
44) After applying A/T fluid to new O-rings (1) and brake drum gaskets (2), install them to automatic transmission case.
45) Install valve body assembly (1) to automatic transmission case and tighten bolts to specified torque.
NOTE:
Be sure to fit manual shift lever pin (2) into groove in manual shift valve (3).
Tightening torque
Valve body bolt ( a ): 11 N·m ( 1.1 kg-m, 8.0 lb-ft)
Valve body bolt length
Bolt Length “a” Pieces
A (4) 28 mm (1.1024 in.) 5
B (5) 36 mm (1.4173 in.) 3
C (6) 20 mm (0.7874 in.) 7
D (7) 32 mm (1.2598 in.) 1
46) Install valve body harness connector (1) and tighten valve body harness connector fixing bolt (2) to specified torque.
Tightening torque
Valve body harness connector fixing bolt ( a ): 5.5 N·m ( 0.55 kg-m, 4.0 lb-ft)
47) Check wire color or each connector and connect solenoid harness properly.
48) Install A/T fluid temperature sensor (7).
Solenoid valve coupler specification
Solenoid valve coupler Wire color
Shift solenoid No.1 (3) White
Shift solenoid No.2 (4) Black
Timing solenoid valve (5) Yellow
Pressure control solenoid valve (6) Gray + Green
49) After applying A/T fluid to new O-ring (1), install O-ring (1) and oil strainer (2), then tighten 3 bolts to specified torque.
Tightening torque
Oil strainer bolt ( a ): 10 N·m ( 1.0 kg-m, 7.5 lb-ft)
50) Install magnets (1) to oil pan (2).
51) Install oil pan (1) and new gasket (2), then tighten oil pan fixing bolts (3) to specified torque diagonally and little by little.
Tightening torque
Oil pan fixing bolt ( a ): 7.0 N·m ( 0.7 kg-m, 5.0 lb-ft)
52) Install output shaft bearing (1).
53) Using special tool, install new oil seal (1) to rear extension case.
NOTE:
Use new oil seal and apply grease to it.
Special Tool
(A) : 09913–84510
(B) : 09926–26020
: Grease 99000–25010 ( SUZUKI Super Grease A )
54) Apply sealant to rear extension case (1) over transmission installation surface, install it to transmission case and tighten 8 bolts to specified torque.
Tightening torque
Rear extension case bolt ( a ): 25 N·m ( 2.5 kg-m, 18.0 lb-ft)
“A” : Sealant 99000–31230 ( SUZUKI Bond No.1216B )
55) Install transmission range sensor (1) to manual shift lever shaft (2).
56) Turn manual shift lever shaft (2) counterclockwise fully, return it by 2 notches to set it to “N” range.
57) Tighten lock nut (3) to specified torque and fix it by bending its claws of new lock washer (4).
Tightening torque
Lock nut ( a ): 7.0 N·m ( 0.7 kg-m, 5.0 lb-ft)
58) With “N” range reference line (5) and center line of manual shift lever shaft (2) aligned, tighten transmission range sensor fixing bolt (6) to specified torque.
NOTE:
Use new transmission range sensor bolt as it is precoat bolt.
Tightening torque
Transmission range sensor bolt ( b ): 13 N·m ( 1.3 kg-m, 9.5 lb-ft)
59) Install fluid cooler pipe (1), then tighten oil cooler pipe bolt (2) and union bolt (3) to specified torque.
NOTE:
Use new washer (4) for oil cooler pipe.
Tightening torque
Fluid cooler pipe bolt ( a ): 6.0 N·m ( 0.6 kg-m, 4.5 lb-ft)
Union bolt ( b ): 28.0 N·m ( 2.8 kg-m, 20.5 lb-ft)
60) Install output shaft speed sensor (1) and input shaft speed sensor (2), then tighten bolts to specified torque.
Tightening torque
Output shaft speed sensor bolt ( a ): 5.5 N·m ( 0.55 kg-m, 4.0 lb-ft)
Input shaft speed sensor bolt ( b ): 5.5 N·m ( 0.55 kg-m, 4.0 lb-ft)
NOTE:
Use new O-rings for output shaft speed sensor and input shaft speed sensor and apply A/T fluid to them.
61) Install torque converter noting the following points.
CAUTION:
• Before installing converter, make sure that its pump hub portion is free from nicks, burrs or damage which may cause oil seal to leak.
• Be very careful not to drop converter on oil pump gear.
Damage in gear, should it occur, may cause a critical trouble.
• Install torque converter aligning grooves (1) of torque converter and projection (2) of oil pump drive gear.
• Install torque converter, using care not to damage oil seal of oil pump.
• After installing torque converter, check that distance “a” is within specification.
Torque converter installing position
“a”: 28.80 – 30.18 mm (1.134 – 1.188 in.)
• Check torque converter for smooth rotation.
• Apply grease around cup at the center of torque converter.
“C” : Grease 99000–25010 ( SUZUKI Super Grease A )
3. Torque converter 5. Torque converter housing
4. Flange nut 6. Cup