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Transmission Reassembly

NOTE: For bearing race and thrust bearing locations. See Fig 1 .
CAUTION: Lubricate all components with ATF. Clutch discs should be soaked in ATF for 15 minutes prior to installation. Coat thrust bearings and races with petroleum jelly. Ensure ends of snap rings are not aligned with cutout area of case.
  1. Position transmission case with front facing upward. Assemble low and reverse brake inner piston, reaction sleeve and outer piston. See Figure . Press assembled pistons into case with hand pressure. Using appropriate spring compressor, install piston return spring onto outer piston. Install snap ring.
  2. Install output shaft bearing and race. See Fig 1 . Install brake apply tube into transmission case, aligning locking tab with cutout on valve body side of transmission case. Ensure 4 lugs on underside of brake apply tube fit inside of low and reverse brake piston and leaf spring is properly installed. See Fig 2 .
  3. Remove low and reverse brake reaction plate from planetary gear assembly. See Figure . Align notched lugs of low and reverse brake plates and low and reverse brake backing plate. Install planetary gear assembly into transmission case with notched lugs align with cutout in transmission case. See Fig 3 . Measure low and reverse brake clutch pack clearance. See Figure . Ensure low and reverse brake clearance is within specification. See LOW & REVERSE BRAKE CLEARANCE SPECIFICATIONS  table. Install low and reverse brake reaction plate and snap ring.
    LOW & REVERSE BRAKE CLEARANCE SPECIFICATIONS

    Application Clearance - In. (mm)
    Grand Vitara .024-.103 (.61-2.64)
    Sportage & Tracker .029-.098 (.74-2.49)
    Vitara
    1.6L .022-.090 (.56-2.29)
    2.0L .024-.103 (.61-2.64)
  4. Ensure lugs of brake discs and plates in center support are securely in groves. Hold direct clutch snap ring of planetary sun gear and install center support by aligning oil and bolt holes of center support and transmission case. Install bolts in center support and tighten evenly to specification. See TORQUE SPECIFICATIONS  . Install direct clutch assembly while rotating to align with center support.
  5. If fully installed, splined center of clutch will be even with end of sun gear shaft. Install bearing race, thrust bearing and front bearing race over splined end of intermediate shaft. Install thrust bearing and bearing race on forward clutch. Install forward clutch. Rotate while pushing downward on forward clutch to mesh splines of forward clutch with flukes of direct clutch hub.
  6. Using calipers and appropriate straightedge, measure distance between top of case and forward clutch drum. See Figure . Distance should be equal to measurement recorded during disassembly. If distance is less than recorded measurement, remove forward clutch assembly and then reinstall again.
  7. Install OD case with cutout area of OD case aligned with cutout in transmission case. See Fig 4 . Install thrust washer on OD case and OD planetary gear. Ensure washer lugs align with holes in OD case and planetary gear assembly. Install bearing race on OD planetary gear assembly.
    Fig 1: Identifying Bearing Race & Thrust Bearing Locations
    G95E21257Courtesy of SUZUKI OF AMERICA CORP.
    Fig 2: Installing Brake Apply Tube & Leaf Spring
    G00047153Courtesy of SUZUKI OF AMERICA CORP.
    Fig 3: Installing Planetary Gear Assembly
    G00047154Courtesy of SUZUKI OF AMERICA CORP.
    Fig 4: Aligning OD Case & Transmission Case Oil Holes
    G93I23828Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  8. Install OD planetary gear assembly with OD direct clutch and OD one-way clutch. Rotate and push OD planetary gear to mesh splines with flukes of discs. Ensure thrust washer does not fall during installation. Using calipers and appropriate straightedge, measure distance between top of case and OD clutch drum. See Figure . Distance should be equal to measurement recorded during disassembly.
  9. Install "O" ring on OD case. Install torque converter housing onto transmission case. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS  . Install thrust bearing onto rear of oil pump. Ensure oil seal rings and "O" ring are installed on oil pump.
  10. Install oil pump into transmission case. Ensure thrust bearing does not fall off oil pump. Coat oil pump retaining bolts below bolt heads with thread sealer. Install bolts and tighten to specification. Ensure input shaft turns freely. Using a dial indicator, check output shaft end play. Position dial indicator against end of output shaft. End play should be .012-.035" (.30-.90 mm).
  11. Apply air pressure to specified oil passages to check appropriate operating components. See Figure . Component application should be heard while applying air. Install NEW oil seals in transmission case. Lubricate oil seal lips prior to installation. Install NEW spacer on manual valve lever. Install manual valve shaft into case and through manual valve lever. Install NEW pin with slot at right angle to shaft. See Figure .
  12. Align spacer hole to hollow area of lever. Stake spacer to lever. Ensure manual valve shaft turns smoothly. Install parking lock pawl, pivot pin and spring into transmission case. Install lock rod on manual valve lever and install parking lock pawl. Install parking pawl bracket onto transmission case. Ensure collar on control rod is toward front of transmission. Tighten bracket bolts to specification. See TORQUE SPECIFICATIONS  .
  13. Check operation of park lock pawl. Ensure output shaft is locked when manual valve lever is in Park. Determine proper accumulator piston locations. See Figure . Ensure accumulator piston is proper diameter. See ACCUMULATOR PISTON DIAMETER  table. Determine proper spring free length and outer diameter for accumulator piston application. See appropriate ACCUMULATOR SPRING SPECIFICATIONS table.
    ACCUMULATOR PISTON DIAMETER (1)

    Application Diameter - In. (mm)
    Forward & Direct Clutch 1.252-1.254 (31.80-31.85)
    No. 2 Brake 1.370-1.372 (34.80-34.85)
    (1) See illustration for accumulator piston locations. See Figure .
    ACCUMULATOR SPRING SPECIFICATIONS (GRAND VITARA)(1)

    Application Free Length - In. (mm)
    Forward Clutch Spring
    Upper 2.546 (64.68)
    Lower N/A
    No. 2 Brake Spring
    Upper 2.135 (58.80)
    Lower 1.383 (35.13)
    Direct Clutch Spring
    Upper 1.715 (43.56)
    Lower 1.213 (30.80)
    (1) See illustration for accumulator piston locations. See Figure .
    ACCUMULATOR SPRING SPECIFICATIONS (SPORTAGE & TRACKER)(1)

    Application Free Length - In. (mm)
    Forward Clutch Spring
    Upper 2.251 (57.18)
    Lower 1.161 (29.49)
    No. 2 Brake Spring
    Upper 2.172 (55.18)
    Lower 1.383 (35.13)
    Direct Clutch Spring (2) 2.172 (55.18)
    (1) See illustration for accumulator piston locations. See Figure .
    (2) On Tracker, free length is 1.667" (42.35 mm).
    ACCUMULATOR SPRING SPECIFICATIONS (VITARA)(1)

    Application Free Length - In. (mm)
    Forward Clutch Spring
    Upper 2.546 (64.68)
    Lower N/A
    No. 2 Brake Spring
    Upper 2.172 (55.18)
    Lower 1.383 (35.13)
    Direct Clutch Spring
    Upper
    1.6L 2.410 (61.21)
    2.0L 2.355 (59.82)
    Lower N/A
    (1) See illustration for accumulator piston locations. See Figure .
  14. Install accumulator pistons and springs. Ensure accumulator pistons are pressed fully into bore. Install NEW "O" rings on throttle cable fitting. Install throttle cable. Align manual valve with pin on manual valve lever. Connect throttle cable to cam. Install valve body assembly and valve body bolts in proper position. See Figure . Tighten valve body bolts to specification. See TORQUE SPECIFICATIONS  .
  15. Install gasket and oil strainer. Tighten bolts to specification. Using a plastic hammer, install oil tubes. See Figure . DO NOT bend or damage oil tubes. Install magnets in oil pan. Ensure magnets do not interfere with oil tubes. Install NEW oil pan gasket to transmission case. Align gasket with transmission case. Install oil pan bolts and tighten to specification.
  16. Install speed sensor rotor and snap ring. Install extension housing with NEW gasket. Install extension housing bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  17. Fully turn manual valve shaft forward and return 2 notches. Install TR switch on manual valve shaft and temporarily tighten adjusting bolt. Install lock washer and set nut. Torque set nut to 35 INCH lbs. (4 N.m). Bend over at least 2 washer tabs.
  18. With Neutral reference line and cut-out on TR switch aligned, tighten switch retaining bolt to 44 INCH lbs. (5 N.m).
  19. Install control shaft lever with spring washer and nut. Tighten nut to 115 INCH lbs. (13 N.m). Install wire harness and throttle cable clamp. Install torque converter. Ensure torque converter is installed correctly. Using a straightedge and calipers, measure torque converter depth. See TORQUE CONVERTER INSTALLED DEPTH SPECIFICATIONS  table. See Fig 5 .
    TORQUE CONVERTER INSTALLED DEPTH SPECIFICATIONS

    Application (1) Distance - In. (mm)
    Grand Vitara .685 (17.40)
    Sportage & Tracker .669 (17.00)
    Vitara
    1.6L .846 (21.50)
    2.0L .681 (17.30)
    (1) See Fig 5 .
Fig 5: Measuring Torque Converter Installed Depth
G95F21258Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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