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Valve Body: Reassembly

  1. Install valves and springs into torque converter side of front valve body. See Figure . Ensure correct spring and valve are installed in appropriate bore. See VALVE BODY SPRING IDENTIFICATION  table.
  2. Install check balls, check valve, spring and solenoid oil strainers. See Fig 1 . Install gaskets, plate and front valve body cover. Tighten bolts to 60 INCH lbs. (6.8 N.m).
    Fig 1: Check Valve & Spring Location (Front Valve Body)
    G96F30556Courtesy of SUZUKI OF AMERICA CORP.
  3. Install valves and springs into rear cover side of front valve body. See Figure . Ensure correct spring and valve are installed in appropriate bore. See VALVE BODY SPRING IDENTIFICATION  table.
  4. Install accumulator pistons, valves and springs into rear valve body. See Figure . Ensure correct spring and valve are installed in appropriate bore. See VALVE BODY SPRING IDENTIFICATION  table. DO NOT  reuse accumulator "O" ring.
  5. Install check balls and accumulator spring into rear valve body covers. See Fig 2 . Install gaskets, plates and rear valve body covers with check balls and accumulator spring. See Fig 3 . Tighten bolts to 96 INCH lbs. (10.8 N.m).
  6. Install check balls, solenoid oil strainer, check valves and springs into rear valve body. Make sure the correct spring is installed in the appropriate bore. See Fig 4 . Also, refer to the CHECK VALVE SPRING IDENTIFICATION  table.
  7. Place gaskets and plate on rear valve body. Ensure "AO" mark faces front valve body side. Place check valve and spring into front valve body. See Fig 5 .
  8. Install rear valve body with gaskets, plate and inner parts to front valve body. Tighten bolts to 60 INCH lbs. (6.8 N.m). Install solenoid control valves to valve body. Tighten bolt to 60 INCH lbs. (6.8 N.m). Install manual valve.
CHECK VALVE SPRING IDENTIFICATION (1)

Spring I.D. Length: In. (mm) O.D.: In. (mm) Color
No. 1
Option 1 .496 (12.60) .205 (5.21) Blue
Option 2 .470 (11.94) .200 (5.08) White
No. 2
Option 1 .713 (18.11) .244 (6.20) Yellow
Option 2 .670 (17.02) .240 (6.10) Yellow
(1) Manufacturer shows 2 different available springs for each check valve, but does not identify application. Verify spring measurement with spring color and reinstall into bore from which it was removed. See Fig 4 .
Fig 2: Rear Cover Check Ball & Spring Location
G96G30557Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Assembling Rear Valve Body Covers
G96H30558Courtesy of SUZUKI OF AMERICA CORP.
Fig 4: Rear Valve Body Check Ball & Spring Location
G96I30559Courtesy of SUZUKI OF AMERICA CORP.
Fig 5: Check Valve & Spring Location (Front Valve Body)
G96B30560Courtesy of SUZUKI OF AMERICA CORP.
VALVE BODY SPRING IDENTIFICATION

Spring I.D. Length: In. (mm) O.D.: In. (mm) Color
1-2 Shift Valve 1.340 (34.0) .310 (7.9) Blue
2-3 Shift Valve 1.340 (34.0) .310 (7.9) Blue
3-4 Shift Valve 1.340 (34.0) .310 (7.9) Blue
TCC Modulator Valve 1.100 (27.9) .310 (7.9) Green
2nd/4th Brake Modulator Valve 1.180 (30.0) .330 (8.4) Lt. Green
Accum. Control Valve .980 (24.9) .450 (11.4) Purple
Primary Reg. Valve 1.890 (48.0) .520 (13.2) White
2nd/4th Brake Accumulator Piston 1.110 (28.2) .830 (21.1) Blue
Reverse Clutch Accum. Piston (Outer) 1.650 (41.9) .830 (21.1) Red
Reverse Clutch Accum. Piston (Inner) 1.650 (41.9) .610 (15.5) Red
Sol. Modulator Valve 1.120 (28.4) .310 (7.9) Purple
Low Coast Modulator Valve 1.290 (32.8) .300 (7.6) Red
2nd/4th Brake Modulator Control Valve .940 (23.9) .300 (7.6) Pink
Secondary Reg. Valve 1.890 (48.0) .370 (9.4) None
TCC Control Valve 2.560 (65.0) .380 (9.7) None
Coast Clutch Modulator Valve 1.400 (35.6) .300 (7.6) Lt. Green
2-3 Timing Valve .830 (21.1) .430 (10.9) White
OD Clutch Accum. Piston 1.780 (45.2) .830 (21.8) Lt. Green
Forward Clutch Accum. Piston (Outer) 1.650 (41.9) .830 (21.8) Red
Forward Clutch Accum. Piston (Inner) 1.650 (41.9) .610 (15.5) Red
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