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Transmission Reassembly

NOTE: Coat all oil sealing rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cut-outs and are installed correctly in groove. If a worn bushing is to be replaced, replacement must be made with subassembly containing that bushing. Check thrust bearings and races for wear or damage. Use petroleum jelly to hold parts in place. Replace parts as necessary. Soak clutch plates and brake band in ATF for 2 hours or more prior to installation.
  1. Apply grease to lip portion of NEW manual valve lever shaft oil seal and install into transaxle case. Install manual valve lever and shaft into transaxle case with a NEW spacer and spring pin. See Fig 1 . Rotate spacer about 180 degrees, then stake small hole of spacer using a punch and hammer.
  2. Using Bearing Installer (09926-68310), press outer bearing race into transaxle case. Secure with snap ring. See Fig 2 and Fig 3 . Press outer tapered roller bearing onto counter drive gear. Apply ATF to bearing and install NEW spacer onto counter drive gear. Install assembly into transaxle case.
    Fig 1: Installing Manual Valve Linkage
    G96F30606Courtesy of SUZUKI OF AMERICA CORP.
    Fig 2: Installing Transaxle Case Outer Bearing Race
    G96G30607Courtesy of SUZUKI OF AMERICA CORP.
    Fig 3: Installing Roller Bearing Snap Ring
    G96H30608Courtesy of SUZUKI OF AMERICA CORP.
  3. Using an appropriate bearing installer, press inner tapered roller bearing onto counter drive gear. Clamp Counter Drive Gear Holder (09927-76040) in vise. Place transaxle housing onto holder. Install NEW counter drive gear lock nut. Tighten to 362 ft. lbs. (491 N.m).
  4. Using a push-pull gauge attached to an outer transaxle case bolt hole, measure rotational torque of the transaxle case. See Fig 4 . Specified rotational torque is .7-1.9 INCH lbs. (.08-.21 N.m). Using Counter Drive Gear Socket (09927-26010) and an INCH lb. torque wrench, measure the starting torque of counter drive gear. See Fig 5 . Specified starting torque is .5-3.5 INCH lbs. (.05-.39 N.m).
  5. Using a punch and a hammer, stake NEW lock nut. Install "O" rings coated with ATF onto 1st/reverse brake piston. Install piston into transaxle case. Install brake piston return spring, compress and secure with snap ring.
  6. Install brake flanges, clutch discs and plates in the following order: flange, disc, plate, disc, plate, disc, plate, disc and flange. Install snap ring, ensuring open end does not align with grooved section of transaxle case. See Fig 6 .
    Fig 4: Measuring Transaxle Case Rotational Torque
    G96I30609Courtesy of SUZUKI OF AMERICA CORP.
    Fig 5: Measuring Counter Drive Gear Starting Torque
    G96B30610Courtesy of SUZUKI OF AMERICA CORP.
    Fig 6: Installing Brake Flange Snap Ring
    G96C30611Courtesy of SUZUKI OF AMERICA CORP.
  7. Using a dial indicator, measure 1st/reverse brake piston stroke. Measure piston stroke while applying 57-113 psi (4-8 kg/cm2 ) of compressed air to oil hole "A". See Figure . Specified piston stroke is .055-.087" (1.4-2-2 mm).
  8. Place 2nd/4th brake spring into transaxle case. Install 2nd/4th brake piston with NEW "O" rings. Install piston cover, compress using appropriate press and secure with snap ring.
  9. Temporarily install piston rod with lock plate, NEW lock washer and lock nut to transaxle case. Ensure tip of piston rod protrudes into inner side of transaxle case about .079-.118" (2.0-3.0 mm). See Fig 7 and Fig 8 .
  10. Apply ATF to outer surface of locating pins and install into transaxle case. See Fig 9 . Ensure correct pin is installed in its proper place. See LOCATING PIN IDENTIFICATION  table.
    Fig 7: Installing Piston Rod & Lock Plate
    G96D30612Courtesy of SUZUKI OF AMERICA CORP.
    Fig 8: Piston Rod Protrusion
    G96E30613Courtesy of SUZUKI OF AMERICA CORP.
    Fig 9: Transaxle Case Locating Pin Position
    G96F30614Courtesy of SUZUKI OF AMERICA CORP.
  11. Apply ATF to transaxle lubrication tube and install. Tighten to 48 INCH lbs. (5.4 N.m). Install 2nd/4th brake band. Install 1st/reverse clutch assembly. Temporarily install front pump. Temporarily tighten transaxle housing to case with 5-6 bolts. Stand transaxle on end (housing facing downward).
  12. Install front and rear planetary carrier while rotating back and forth. Install sun gear with needle roller bearing. Coat bearing race with grease and install into planetary carrier.
  13. Install overdrive/coast clutch while rotating back and forth. Ensure overdrive/coast clutch locks when turned counterclockwise, and turns freely clockwise. Install forward clutch while rotating.
  14. Using a caliper and straightedge, check for correct installation of components as follows: measure distance "A" (case surface to bottom of straightedge). See Fig 10 . Specified measurement is 1.848-1.882" (46.9-47.8 mm). Remove components and reinstall them properly if not within specification.
    Fig 10: Measuring Forward Clutch Drum Height
    G96G30615Courtesy of SUZUKI OF AMERICA CORP.
  15. Apply Sealant (99000-31160) to mating surface of transaxle case. Install 5 gaskets ("O" rings). Install transaxle rear cover and left-side engine mounting bracket. Install 8 existing bolts. Install 2 NEW bolts in position "A". See Figure . Tighten bolts to 18 ft. lbs. (25 N.m).
  16. Turn transaxle over. Remove transaxle housing. Remove front pump, 1st/reverse clutch and 2nd/4th brake band from transaxle case. Apply ATF to bearing race with integrated needle roller bearing. Install counter driven gear.
  17. Install parking lock rod with parking lock pawl, parking lock pawl bracket and torsion spring. See Fig 11 . With spacer and torsion spring in place, install bolt and tighten parking lock pawl bracket. Tighten bolt to 90 INCH lbs. (10.2 N.m). Insert parking lock rod to pawl bracket and connect parking lock rod with manual valve lever.
  18. Install 2nd/4th brake band. Install 1st/reverse clutch while rotating back and forth. Using a caliper and straightedge, check for correct installation of input shaft as follows: measure distance "A" (case surface to top of input shaft). See Fig 12 . Specified measurement is 3.372-3.401" (85.6-86.4 mm). Remove input shaft with 1st/reverse clutch and reinstall them properly if not within specification.
    Fig 11: Installing Parking Lock Pawl Linkage
    G96H30616Courtesy of SUZUKI OF AMERICA CORP.
    Fig 12: Measuring Input Shaft Height
    G96I30617Courtesy of SUZUKI OF AMERICA CORP.
  19. Install manual detent spring. Tighten bolts to 90 INCH lbs. (10.2 N.m). Install oil strainer. Install oil reservoir plate. Tighten bolts to 48 INCH lbs. (5.4 N.m).
  20. Adjust 2nd/4th brake piston rod as follows: fully tighten piston rod by hand. loosen piston rod counterclockwise 3-3 1/3 turns. Tighten lock nut to 15 ft. lbs. (11 N.m). Using a punch and a hammer, stake NEW lock nut with lock washer.
  21. Install NEW "O" ring coated with ATF onto brake piston cover. Install brake piston cover into case and secure with snap ring. Install 3 NEW gaskets ("O" rings) in positions shown. See Fig 13 . Tighten 6 oil pump body bolts. Tighten bolts to 18 ft. lbs. (25 N.m).
  22. Apply Sealant (99000-31160) to transaxle case as shown. See Fig 13 . Install transaxle housing to transaxle case. Tighten bolts to 22 ft. lbs. (16 N.m). Ensure NEW bolts are used in position "A". See Figure .
  23. Insert solenoid harness connectors. Coat 2 NEW gaskets ("O" rings) with ATF and install as shown. See Fig 14 . Install valve body assembly and transaxle side cover. See VALVE BODY ASSEMBLY  under ON-VEHICLE SERVICE.
  24. Install solenoid coupler, VSS, forward clutch cylinder revolution sensor, oil filler tube and speedometer driven gear. Ensure NEW "O" rings are used. Tighten fasteners to 48 INCH lbs. (5.4 N.m).
    Fig 13: "O" Ring & Sealant Placement
    G96J30618Courtesy of SUZUKI OF AMERICA CORP.
    Fig 14: Solenoid Harness & "O" Ring Placement
    G96A30619Courtesy of SUZUKI OF AMERICA CORP.
  25. Install TR switch assembly. Place NEW rubber plate and lock washer on TR switch. Tighten lock nut to 60 INCH lbs. (6.8 N.m). Adjust TR switch. See TRANSMISSION RANGE (TR) SWITCH  under ON-VEHICLE SERVICE. Tighten manual shift lever spring washer and nut to 60 INCH lbs. (6.8 N.m).
  26. Install oil cooler pipes and tighten to 26 ft. lbs. (35 N.m). Using an INCH lb. torque wrench, measure starting torque of differential gear assembly. See Figure . Specified starting torque is 12 INCH lbs. (1.4 N.m). Install torque converter onto input shaft.
  27. Using a caliper and straightedge, measure torque converter set-back. See Fig 15 . Specified depth is .929-1.002" (23.6-25.4 mm). Check torque converter for smooth rotation.
LOCATING PIN IDENTIFICATION

Locating Pin Length: In. (mm) O.D.: In. (mm)
A 1.770 (45.0) .310 (7.9)
B 1.330 (33.8) .390 (9.9)
C 1.810 (46.0) .470 (11.9)
Fig 15: Measuring Torque Converter Set-Back
G96D30620Courtesy of SUZUKI OF AMERICA CORP.
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