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Transmission Disassembly

CAUTION: Thoroughly clean transaxle exterior prior to disassembly. Use special care in handling aluminum components. DO NOT turn transaxle over when removing side cover. Turning transaxle may contaminate valve body with foreign matter from bottom of transaxle.
  1. Remove torque converter. Using an INCH-lb. torque wrench, measure starting torque of differential gear assembly. Specified starting torque is 9-12 INCH lbs. (1.0-1.4 N.m).
  2. Remove oil cooler pipes and discard washers. Remove manual shift lever. Remove lock nut and lock washer. Discard lock washer. Remove lock washer and rubber plate. Remove 2 bolts, and Transmission Range (TR) switch.
  3. Remove oil level dip stick, filler tube, forward clutch cylinder revolution sensor and each Vehicle Speed Sensor (VSS). One VSS is used for TCM input, the other is used for speedometer input.
  4. Remove transaxle housing and discard 2 non-reusable bolts at position "A". See Fig 1 . Pull out differential gear assembly. Clean mating surfaces between transaxle case and housing. Remove 3 gaskets from transaxle case side. Remove oil pump body retaining bolts, then oil pump body.
    Fig 1: Identifying NEW Transaxle Housing Bolt Locations
    G96G30532Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove 2 bolts, oil reserve plate and oil strainer. Remove the manual detent spring. Remove the valve body assembly. See VALVE BODY ASSEMBLY  under ON-VEHICLE SERVICE. Remove 2 gaskets ("O" rings). Using snap ring pliers, remove snap ring and pull out brake cover.
  6. Using a dial indicator, measure 2nd-4th brake piston stroke as follows:
    • Plug oil hole "A". See Fig 2 .
    • Measure piston stroke while applying and releasing 57-113 psi (4-8 kg/cm2 ) of compressed air at oil hole "B".
    • Specified piston stroke is .078-.095" (2.0-2.4 mm).
      Fig 2: Measuring 2nd-4th Brake Piston Stroke
      G96H30533Courtesy of SUZUKI OF AMERICA CORP.
  7. Pry off lock section of lock washer, loosen lock nut and remove piston rod with lock nut, lock washer and lock plate. NEVER reuse old lock washer. Remove lock plate from piston rod.
  8. Pull out reverse clutch assembly. Remove 2nd-4th brake band assembly. Remove straight pin. Ensure length of straight pin is 1.770" (45 mm), and diameter is .310" (7.9 mm).
  9. Using an appropriate press, push in piston cover and remove snap ring. Remove 2nd-4th brake piston cover, piston and spring. Remove 6 bolts from transaxle rear cover. Using a plastic hammer, tap 2 rib sections of rear cover. Remove 10 bolts and left-side engine mounting bracket. Discard 2 non-reusable bolts at position "A". See Fig 3 .
    Fig 3: Identifying New Rear Cover Bolt Location
    G96I30534Courtesy of SUZUKI OF AMERICA CORP.
  10. Pull out transaxle rear cover with forward clutch subassembly installed. Remove 5 gaskets ("O" rings). Remove carrier for front/rear planetary ring gear and sun gear assembly with integral bearing installed. Pull out sun gear assembly.
  11. 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 Fig 4 . Specified piston stroke is .055-.087" (1.4-2.2 mm).
    Fig 4: Measuring 1st-Reverse Brake Piston Stroke
    G96J30535Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove snap ring. Remove pressure plates, clutch discs and clutch plates. Remove retainer ring and brake piston return spring. Apply 57-113 psi (4-8 kg/cm2 ) of compressed air to oil hole "A" to remove 1st-Reverse brake piston. See Fig 4 .
  13. Remove parking lock pawl, pawl bracket and spring. Pry torsion spring from parking lock pawl. Remove parking lock pawl by pulling out pawl shaft with torsion spring installed. Remove counter driven gear assembly.
  14. Remove needle roller bearing with race. Remove lubrication tube. Using an INCH-lb. torque wrench, measure starting torque of counter drive gear subassembly. Specified starting torque is .4-2.2 INCH lbs. (.05-.25 N.m). Unstake lock nut.
  15. Clamp Counter Drive Gear Holder (09927-76040 ) in vise. Place transaxle housing onto holder. Using an appropriate push-pull gauge attached to an outer transaxle case bolt hole, measure transaxle housing rotational torque. Specified rotational torque is .4-1.3 INCH lbs. (.05-.15 N.m). Remove lock nut and discard.
  16. Using Bearing Puller Attachment (09925-86010 ), press out counter drive gear subassembly. Remove counter bearing spacer and discard. Collapse tapered roller bearing outer race of counter drive gear subassembly. Using a 2-jaw puller, remove inner tapered roller bearing race.
  17. Remove snap ring. Using Bearing Installer (09926-68310 ), press outer race from transaxle case. Using a chisel and hammer, collapse manual valve lever shaft spacer. Remove slotted spring pin. Discard spacer and spring pin. Remove manual valve lever shaft subassembly, manual valve lever and oil seal.
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