Transmission Disassembly

Remove torque converter. Remove oil filler tube and dipstick. On 4WD models, remove transfer case-to-transmission adapter. On 2WD models, remove extension housing. On all models, remove vent hose. Remove snap ring from output shaft and remove vehicle speed sensor rotor.
Remove manual valve lever from manual valve shaft. Remove lock plate from Transmission Range (TR) switch. Remove TR switch. Remove oil pump bolts. Using appropriate 2-jaw puller, remove oil pump from transmission case. Remove bearing and race from rear of oil pump. Remove torque converter housing bolts. Note length and bolt location. While holding OD input shaft, remove torque converter housing. Remove "O" ring from transmission case.
Remove oil pan and gasket. Remove magnets from oil pan. Inspect magnets and pan for metal particles. Remove oil tubes by carefully prying both ends of tube with screwdriver. See Fig 1 . Remove solenoid wiring harness from transmission case. Remove oil strainer (filter) and gasket.

Fig 1: Identifying Oil Tube Locations
Courtesy of SUZUKI OF AMERICA CORP.
Remove valve body assembly retaining bolts, start with outermost bolts and work inward. Lift valve body and disconnect throttle cable from throttle cam. Remove valve body assembly.
Remove throttle cable and "O" ring. Place a clean shop cloth over accumulator pistons. Apply compressed air to oil passages of transmission case to remove accumulator pistons and springs. Oil passages are at base of accumulator bores. Note spring and piston locations. See Fig 2 .
Remove parking lock rod bracket and rod. Remove parking lock pawl, pivot pin and spring. If manual valve shaft requires removal, use a hammer and chisel to cut spacer and slide spacer toward lever to obtain clearance to shaft pin. Drive out roll pin. Remove shaft and spacer. Remove oil seals. See Fig 3 .
Position transmission case with front of case facing upward. Push input shaft and drum toward rear of transmission case to ensure OD direct clutch remains fully seated. Using calipers and appropriate straightedge, measure distance between top of case and OD direct clutch drum. See Fig 4 .
Record measurement for reassembly reference. Remove OD planetary gear with OD direct clutch and OD one-way clutch from OD case. See Fig 5 . Note location of thrust washer and race on clutch assembly. Hold both sides of OD case and remove from transmission case. Note location of bearing and race.
Ensure forward clutch remains fully seated in transmission case. Using calipers and appropriate straightedge measure distance between top of case and forward clutch drum. See Fig 6 . Record measurement for reassembly reference.

Fig 2: Identifying Accumulator Pistons & Springs
Courtesy of SUZUKI OF AMERICA CORP.

Fig 3: Exploded View Of Manual Shaft Lever & Shaft
Courtesy of KIA MOTORS AMERICA, INC.

Fig 4: Measuring OD Direct Clutch Drum-To-OD Case Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig 5: Identifying Transmission Case Internal Components
Courtesy of MAZDA MOTORS CORP.

Fig 6: Measuring Forward Clutch Drum-To-Transmission Case Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Remove forward clutch assembly from transmission case. Note location of bearings and race. Remove direct clutch assembly from transmission case. See Fig 5 . Remove center support-to-case retaining bolts. Bolts are located on valve body side of case.
Remove center support, sun gear and No. 1 one-way clutch from transmission case. Note direction of bearing race on end of sun gear. Using a flat-blade screwdriver, remove front planetary gear snap ring. Remove front and rear planetary gear assemblies, No. 2 one-way clutch and output shaft.
Remove brake apply tube from transmission case. Remove brake applying cover. See Fig 9 . Remove race from transmission case.
Using appropriate spring compressor, compress low and reverse brake return spring. Remove snap ring. Remove piston return spring. Hold outer reverse piston with hand, apply compressed air to appropriate oil supply port in case and remove outer reverse piston. See Fig 10 . Gradually lift reaction sleeve out of transmission case. Lift inner reverse piston out of transmission case. See Fig 7 .

Fig 7: Locating Low & Reverse Brake Components

Courtesy of KIA MOTORS AMERICA, INC.

Fig 8: Measuring Reverse Brake Pack Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig 9: Locating Brake Applying Cover

Courtesy of SUZUKI OF AMERICA CORP.

Fig 10: Identifying Oil Supply Ports

Courtesy of SUZUKI OF AMERICA CORP.