Transmission Disassembly

Remove torque converter. Remove oil filler tube. Remove vent hose and speed sensor. Unbolt and remove transfer case-to-transmission adapter or extension housing. Remove snap ring from output shaft and remove speed sensor rotor.
Remove manual lever from manual shaft. Remove lock plate from Park/Neutral Position (PNP) switch. Remove PNP switch. Remove oil pump bolts. Using appropriate 2-jaw puller, remove oil pump from transmission case. Remove bearing and race from rear of oil pump. Remove torque converter housing bolts. Note length and bolt location. While holding OD input shaft, remove torque converter housing. Remove "O" ring from transmission case.
Remove oil pan and gasket. Remove magnets from oil pan. Inspect magnets and pan for metal or brass particles. Remove oil tubes by carefully prying both ends of tube with screwdriver. See Fig 1 . Remove solenoid wiring harness from transmission case. Remove oil strainer (filter) and gasket. Remove valve body assembly. See VALVE BODY ASSEMBLY under ON-VEHICLE SERVICE.

Fig 1: Identifying Oil Tube Locations
Courtesy of SUZUKI OF AMERICA CORP.
Remove throttle cable and "O" ring. Place a clean shop cloth over accumulator pistons. Apply compressed air to oil passages of transmission case to remove accumulator pistons and springs. Air passages are at base of accumulator bores. See Fig 2 . Note spring and piston locations.
Remove parking lock rod bracket and rod. Remove parking lock pawl, pivot pin and spring. If manual valve lever shaft requires removal, use a hammer and chisel to cut spacer and slide spacer toward lever to obtain clearance to shaft pin. Drive out roll pin. Remove shaft and spacer. Remove oil seals.
Position transmission case with front of case facing upward. Push input shaft and drum toward rear of transmission case to ensure OD direct clutch is installed correctly. Using calipers and appropriate thrust plate gauge (straightedge), measure distance between top of case and OD direct clutch drum. See Fig 3 .
Record measurement for reassembly reference. Remove OD planetary gear with OD direct clutch and one-way clutch from OD case. Note location of thrust washer and race on clutch assembly. Hold both sides of OD case and remove from transmission case. Note location of bearing and race. See Fig 4 .
Push input shaft and drum toward rear of transmission case. Ensure forward clutch is installed correctly. Using calipers and thrust plate gauge (straightedge) measure distance between top of case and forward clutch drum. See Fig 5 . Record measurement for reassembly reference.

Fig 2: Identifying Accumulator Pistons & Springs
Courtesy of SUZUKI OF AMERICA CORP.

Fig 3: Measuring OD Direct Clutch Drum Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig 4: Identifying Transmission Case Internal Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig 5: Measuring Forward Clutch Drum Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Remove forward clutch assembly from transmission case. Note location of bearings and race. Remove direct clutch assembly. Remove center support-to-case retaining bolts. Bolts are located at valve body side of case.
Remove center support and sun gear assembly from transmission case. Note direction of bearing race on end of sun gear. Using 2 screwdrivers, remove front planetary gear snap ring. Remove snap ring. Insert 2 wires into planetary gear and remove gear. Using calipers, measure pack clearance of reverse brake between disc and transmission case. See Fig 6 . Pack clearance should be .029-.098" (.74-2.50 mm). If clearance is not as specified, inspect brake discs.
Remove reverse brake pack and pressure plate. Remove rear planetary gear, output shaft and 2 bearings. Remove brake applying cover. See Fig 7 . Remove race from transmission case. Ensure reverse brake pistons move smoothly when applying compressed air into transmission case. See Fig 8 .
Using appropriate spring compressor, compress 1st and reverse brake return spring. Remove snap ring. Remove piston return spring. Hold outer piston with hand, apply compressed air to case and remove outer piston. Gradually lift reaction sleeve out of transmission case. Lift piston out of transmission case. See Fig 4 .

Fig 6: Measuring Reverse Brake Pack Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig 7: Locating Brake Applying Cover

Courtesy of SUZUKI OF AMERICA CORP.

Fig 8: Identifying Oil Supply Ports

Courtesy of SUZUKI OF AMERICA CORP.