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Transmission Reassembly

NOTE: Coat all oil seal 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 in ATF for at least 2 hours prior to installation.
  1. Place 2nd brake piston spring in transaxle case. Apply ATF to piston rod, seal and seal ring. Insert 2nd brake piston into case. Apply ATF to 2 cover seals. Install piston cover. Using valve spring compressor, push down piston cover and install snap ring. See Figure.
  2. Install lower washer and parking lock rod on manual shift shaft. See Fig 1. Carefully install manual shift shaft into transmission case. Install manual detent spring. Tighten manual detent spring bolt and nut to 106 INCH lbs. (12 N.m). Install shift shaft upper washer and manual shift lever to manual shift shaft. Tighten shift shaft lower nut first, then tighten upper nut to 24 ft. lbs. (33 N.m). Check manual shift shaft for smooth rotation.
    Fig 1: Exploded View Of Manual Shift Shaft & Parking Lock Pawl
    G93C24499Courtesy of SUZUKI OF AMERICA CORP.
  3. Install restrictor pin and snap ring to parking lock pawl sleeve. Install assembly into case. Shift manual shift lever to a position other than "P". Install parking lock pawl. Install lock pawl shaft and lock pawl spring. Ensure parking lock pawl moves smoothly when manual shift lever is activated.
  4. Apply ATF to 1st and reverse brake piston inner and outer seals. Install new seals on piston. Carefully insert 1st and reverse piston with spring holes facing upward. Place return spring on piston. Push down on return spring and install snap ring. See Fig 2.
  5. Install countershaft. Ensure countershaft spacer is installed in correct position. DO NOT use excessive force when hammering shaft into position.
  6. Shift manual shift lever to position other than "P". Using bearing installer, install output shaft. Shift manual shift lever to "P" so output shaft is locked and cannot turn. Install reduction driven gear on countershaft. Tighten driven gear nut to 108 ft. lbs. (150 N.m). Stake driven gear nut in 2 places.
  7. Install transaxle rear cover gasket. Install rear cover. Ensure output shaft bearing enters rear cover bearing hole smoothly. Install 10 bolts and 2 nuts. Tighten rear cover bolts to 12-17 ft. lbs. (16-23 N.m). Tighten rear cover nuts to 8-11 ft. lbs. (11-15 N.m). Ensure shafts rotate smoothly.
  8. Push output shaft against rear cover side. Fit 4 projections of output shaft installer to 4 notches in case. To prevent damage to shaft, DO NOT hit output shaft directly.
  9. Line up final gear and countershaft gear teeth. Carefully drive in differential by applying pressure to side bearing inner race using bearing installer.
  10. Install 1st and reverse brake damper plate on return spring with convex side facing upward. Install in order: plate, disc, plate, disc, plate, disc, plate and disc. Install flange with flat area facing inward. Install snap ring. Measure 1st and reverse brake clutch clearance. Measure clearance between snap ring and flange. See Figure. Standard clearance should be .023-.075" (.58-1.91 mm). Check 1st and reverse brake piston operation by applying compressed air into oil hole. Confirm 1st and reverse brake piston moves smoothly.
  11. Align ring gear and output shaft spline and insert rear planetary ring gear. See Fig 2. Install rear planetary ring gear races and bearing. Ensure ring gear races are installed in proper positions and directions. See Fig 3.
    Fig 2: Exploded View Of 1st & Reverse Brake & Planetary Gears
    G93F24500Courtesy of SUZUKI OF AMERICA CORP.
    Fig 3: Identifying Bearing & Race Locations
    G93H24502Courtesy of SUZUKI OF AMERICA CORP.
  12. Temporarily assemble one-way clutch and rear planetary gear. Check one-way clutch operation. Clutch and gear should rotate freely in arrow direction "A" and lock in the opposite direction. See Fig 4. Remove one-way clutch.
    Fig 4: Checking Free Rotation Of One-Way Clutch
    G93I24503Courtesy of SUZUKI OF AMERICA CORP.
  13. Apply grease to rear planetary thrust washers. Install thrust washers on front and rear faces of rear planetary gear. Ensure washer lugs match slots in planetary gear.
  14. Align 1st and reverse brake discs and install rear planetary gear. Check thrust washers and races for proper installation. Move rear planetary gear up and down lightly by hand. Listen for a click sound which indicates proper installation.
  15. Install one-way clutch race snap ring into groove of transaxle case. Place one-way clutch on rear planetary gear. While turning planetary gear clockwise, insert one-way clutch. Confirm planetary gear turns clockwise and locks counterclockwise.
  16. Install one-way clutch race snap ring. Ensure snap ring end-gap is between lugs. Install sun gear pin and thrust washer on sun gear. Ensure pin is in thrust washer notch. Push in sun gear while engaging with rear planetary gear. DO NOT damage bushing inside sun gear. Check thrust washers for proper installation. Lightly move sun gear up and down. Listen for a click sound which indicates proper installation.
  17. Install front planetary gear bearing and race to sun gear. See Fig 3. Install front planetary gear while turning gear back and forth. Check bearing and race for proper installation. Move planetary gear up and down lightly with finger. If planetary gear makes a clicking sound, bearing and race are properly installed.
  18. Install ring gear bearing and races on front planetary gear. See Fig 3. Install front planetary ring gear. Check bearing and race for proper installation. Move ring gear up and down lightly with finger. If ring gear makes a clicking sound, bearing and race are properly installed.
  19. Install 2nd brake band. DO NOT bend or damage. Check output shaft seal ring for wear or damage. Apply grease to direct clutch washer. Install direct clutch washer on direct clutch with washer grooves facing upward. Align washer protrusions to direct clutch drum groove.
  20. Align direct clutch discs and install direct clutch on input shaft. Check direct clutch for proper installation. Move direct clutch up and down lightly by hand. Listen for a click sound which indicates proper installation. Install ring gear races and bearing. See Fig 5.
    Fig 5: Installing Ring Gear Bearing
    G93J24504Courtesy of SUZUKI OF AMERICA CORP.
  21. While rotating input shaft and direct clutch, insert into case. Align forward clutch discs and install forward clutch. Check input shaft for proper installation. Move input shaft up and down lightly by hand. If input shaft makes a clicking sound, shaft is installed properly.
  22. Place straightedge on transaxle case end surface and measure distance "A" by using vernier caliper. See Fig 6. Distance "A" should be 1.961-2.010" (49.82-51.06 mm). To obtain distance "A", subtract width of straightedge from vernier reading. If distance "A" is within specification, component parts are installed properly. If distance "A" is not within specification, remove input shaft and direct clutch. Reinstall properly.
    Fig 6: Measuring Distance Between Case End Surface & Input Shaft Flange
    G93A24505Courtesy of SUZUKI OF AMERICA CORP.
  23. Align hole in 2nd brake band with case pin hole and insert 2nd brake band pin. Carefully install transaxle case housing and new case gasket. See Fig 7. Install case housing bolts and tighten to 12-17 ft. lbs. (16-23 N.m). DO NOT apply thread locking compound to case housing bolts.
    Fig 7: Installing Case Housing Bolts
    G93B24506Courtesy of SUZUKI OF AMERICA CORP.
  24. Measure input shaft seated position. See Fig 8. Distance "A" should be 7.416-7.477" (188.37-189.92 mm).
    Fig 8: Measuring Input Shaft Seating Position
    G93C24507Courtesy of SUZUKI OF AMERICA CORP.
  25. Install input shaft bearing race and bearing on shaft. Install other input shaft bearing race on oil pump. Ensure seal rings installed in oil pump cover flange are in good condition and lubricated with ATF. Input shaft thrust play is adjusted with oil pump bearing race.
  26. Install direct clutch washer flange into notch of oil pump body. Install new oil pump cover seal to oil pump. Align oil pump bolt hole with bolt hole and gently push oil pump into case. Ensure direct clutch washer does not fall. Ensure smooth rotation of input shaft. Gradually tighten 6 oil pump bolts to 14-20 ft. lbs. (18-27 N.m).
  27. Measure input shaft thrust play. Input shaft thrust play should be .012-.035" (.30-.89 mm). If thrust play is incorrect remove oil pump and replace input shaft bearing race on oil pump side. Oil pump races are available in thicknesses of .031" (.79 mm) and .055" (1.40 mm). Ensure input shaft rotates smoothly.
  28. Install wire harness to case. Check 2nd brake band for proper installation. Ensure 2nd brake piston rod end is aligned with center of recess in brake band. See Fig 9. If rod end contacts outside of brake band recess, pull up 2nd brake band by inserting thin wire in brake band fitting to align band recess with rod end properly. Check 2nd brake piston stroke. See TRANSMISSION DISASSEMBLY  step  4. See Figure. Install 2nd brake band cover with new gasket. Tighten 2nd brake band cover bolts to 66-78 INCH lbs. (7.5-8.8 N.m).
    Fig 9: Checking 2nd Brake Band Alignment
    G93D24508Courtesy of SUZUKI OF AMERICA CORP.
  29. Install oil pressure control cable in case. Install accumulator springs and pistons. Align manual valve with pin on manual shift lever. Ensure manual shift lever pin is between 2 flanges at end of manual shift valve. Lower valve body into position. Install 11 bolts in lower valve body. See Fig 10. Tighten 3 reamer (positioning) bolts "C" and "D". Tighten all lower valve body bolts to 72-102 INCH lbs. (8.1-11.5 N.m).
    Fig 10: Installing Valve Body Bolts
    G93E24509Courtesy of SUZUKI OF AMERICA CORP.
  30. Install oil pressure control cable on throttle valve cam. Using plastic hammer, tap in 2 oil tubes to valve body. DO NOT deform oil tubes. Install direct clutch and 2nd brake solenoid wires. Install oil strainer and solenoid wire clamp. Tighten oil strainer bolts to 44-53 INCH lbs. (5-6 N.m).
  31. Install magnet in oil pan under oil strainer. Install oil pan bolts. Tighten 15 oil pan bolts to 36-48 INCH lbs. (4.1-5.4 N.m). Tighten oil pan drain plug to 14-17 ft. lbs. (19-23 N.m).
  32. Install oil inlet and outlet pipes. Tighten union bolts to 15-17 ft. lbs. (20-23 N.m). Clamp pipes with oil pipe plate through rubber tubes. Tighten 8 mm plate bolts to 89-144 INCH lbs. (10.1-16.3 N.m). Tighten 6 mm plate bolt to 36-60 INCH lbs. (4.1-6.8 N.m).
  33. Insert oil filler tube in case to flange. Tighten oil filler tube bolt to 36-60 INCH lbs. (4.1-6.8 N.m). Install engine mounting LH bracket. Tighten bolts to 37-43 ft. lbs. (50-60 N.m).
  34. Carefully install torque converter to input shaft. Ensure distance "A" is within specification. See Fig 11. Check torque converter for smooth rotation. Apply grease around cup at center of torque converter.
    Fig 11: Installing Torque Converter
    G93H24510Courtesy of SUZUKI OF AMERICA CORP.
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