Transmission Reassembly
NOTE:
Ensure correct thrust bearing and washer placement during reassembly. See Fig 1.
NOTE:
Soak all friction discs and brake band in transmission fluid for at least 15 minutes before reassembly.
- Align tangs of clutch discs in 2nd clutch assembly and install 3rd clutch assembly. Place transmission case facing up. Install brake band. Install thrust washer, thrust bearing and low brake drum (planetary rear sun gear) with rear sun gear thrust washer.
- Place thrust bearing and washer on planetary rear sun gear and install planetary gear carrier. Place thrust washer and bearing into top of planetary carrier. Insert 2nd/3rd clutch assemblies into case.NOTE: Manufacturer does not provide reverse clutch pressure plate thickness specifications for Geo. The following procedure applies to Suzuki only.
- Determine correct reverse clutch pressure plate thickness. Stack steel and lined plates with spring plate on surface plate. Place current pressure plate on top of stack. Compress stack by hand. Using vernier caliper, measure stack height. See Fig 2.
- To determine correct pressure plate, see REVERSE CLUTCH PRESSURE PLATE SELECTION (SIDEKICK) . Install selected pressure place, steel clutch plate, then clutch disc and repeat. End with spring cushion plate.REVERSE CLUTCH PRESSURE PLATE SELECTION (SIDEKICK)
Stack Height: In. (mm) Pressure Plate: In. (mm) .741-.750 (18.82-19.11) .248-.252 (6.30-6.40) .730-.741 (18.53-18.81) .259-.263 (6.59-6.69) .718-.729 (18.24-18.52) .271-.275 (6.88-6.98) .707-.718 (17.95-18.23) .282-.286 (7.17-7.27) - Determine correct input shaft thrust washer. Place Depth Measuring Tool (09923-46010 or J-23085) on flange of case. See Fig 3. Loosen thumb screw and allow plunger to contact thrust face of 2nd clutch housing. Tighten thumb screw.
- Remove measuring tool. Using feeler gauge, measure length of plunger protrusion. Select appropriate thrust washer to obtain .014-.031" (.36-.79 mm) end play and install. See SELECTIVE THRUST WASHER SELECTION .SELECTIVE THRUST WASHER SELECTION
I.D No. Color Thickness 2 Yellow .060-.074 (1.52-1.88) 3 Red .068-.079 (1.73-2.01) 4 Black .075-.084 (1.91-2.13) 5 Natural .083-.089 (2.11-2.26) 6 Green .090-.094 (2.29-2.39) 7 Blue .095-.102 (2.41-2.59) - Install reverse clutch, oil pump and converter housing assembly. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS . Inspect input shaft end play. Ensure end play is .014-.031" (.36-.79 mm). If end play is not within specification, select alternate thrust washer and remeasure.
- Install "O" ring on input shaft. Install governor assembly on back end of transmission. Install snap ring, speedometer drive gear and snap ring. Install extension housing or transfer case (as applicable).
- Install servo piston return spring and piston rod into case. Install servo piston. Ensure adjustment bolt is loose. Using Servo Compressor (09927-66020 or J-23075), compress servo piston assembly and install snap ring. See Figure.
- Adjust brake band. Secure servo piston sleeve with wrench. Turn adjustment bolt until it contacts band. Using torque wrench, tighten adjustment bolt to 40 INCH lbs. (4.5 N.m). Back off adjustment bolt EXACTLY 5 turns and tighten lock nut.
- Install lever and select shaft. Tighten nut on end of shaft. Install roll pin in manual select shaft. Install park/neutral position switch. Install check ball in case oil passage. See Figure.
- Install valve body onto case with new gaskets and separator plate. Ensure manual valve link is attached to select lever. Tighten valve body bolts to specified torque. See TORQUE SPECIFICATIONS . See Fig 4.
- Install detent roller assembly. Install filter (screen). Install reinforcement plate. Install oil pressure switch. Install TCC solenoid with oil pipes. Install and connect wiring harness. Install servo cover.
- Install kick-down cable. Install oil pan with magnets. Install oil cooler pipes. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install torque converter. Measure converter installed depth to confirm correct installation. See Fig 5. Depth on Sidekick should be 1.21-1.33" (30.67-33.83 mm). Depth on Tracker should be .83-.91" (21.2-23.2 mm).