Transmission Disassembly
- Remove oil pan and filter. Remove manual detent roller assembly. Remove TCC solenoid and harness assembly. Remove governor pressure switch from valve body. Remove reinforcement plate under TCC solenoid. Remove servo cover.
- Unbolt and remove valve body with manual valve, link, separator plate and gaskets. Remove check ball in transmission case. See Fig 1. Using Servo Compressor (09927-66020 or J-23075), compress servo piston assembly and remove snap ring. See Fig 2.
- Remove compressor. Remove servo assembly with spring and rod. Remove Park/Neutral Position (PNP) switch. Pull roll pin from manual select shaft. Place a metal plate between manual select shaft inner lever and case. Loosen nut on end of shaft and remove. Remove lever and select shaft.
- Remove extension housing or transfer case. Remove modulator and modulator plunger. Remove roll pin from kickdown valve sleeve. Remove remaining kickdown valve components. See Fig 3. Remove speedometer gear retaining snap ring, gear and snap ring.
- Remove governor hub. Remove governor from hub. Remove small filter screen from hub. See Fig 4. Remove "O" ring from input shaft. Remove bolts securing converter housing to transmission case.
- Remove housing, oil pump and reverse clutch piston as complete assembly. Remove 2nd and 3rd clutch assemblies. See Fig 4. Remove remaining reverse clutch plate and pressure plate.
- Remove planetary gear. Remove thrust bearing from top of sun gear if bearing did not stay with planetary gear. Remove rear sun gear assembly. Remove low brake band and any remaining thrust bearing and washer.
- Remove manual select shaft inner lever and parking lock actuator assembly. Separate 2nd clutch from 3rd clutch. Remove electrical harness connector.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.