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Home >> Suzuki >> 2001 >> Vitara JS, 2D Utility, 1.6, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission Overhaul - Aw 03-72LE & Aw 03-73LE >> Component Disassembly & Reassembly >> Valve Body >> Front Upper Valve Body Disassembly
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Front Upper Valve Body Disassembly

NOTE: When disassembling the valve body halves, keep all valve springs, spring seats and plugs within their respective valves. Most valve springs are of different sizes and CANNOT be interchanged. Verify that all parts are clean and dry before assembly.
  1. Remove the throttle valve keep plate from the valve body. See Fig 1 .
  2. Perform the following steps in order to remove the cut back valve and components:
    1. Hold the cut back valve plug using a Flathead screwdriver.
    2. Remove the cut back retainer using a magnet. See Fig 2 .
    3. Remove the cut back plug.
    4. Remove the cut back valve.
    5. Remove the cut back valve spring.
  3. Remove one of the front valve body end cover pressure relief valve bolts. Loosen the other front valve body end cover bolt. Move the end cover away. See Fig 3 . Remove the secondary regulator valve sub assembly. Remove the secondary regulator valve spring. Remove the second front valve body end cover pressure relief valve bolt. Remove the end cover.
  4. Remove the following TV cable cam components:
    • The bolt. See Fig 4 .
    • The cam.
    • The return spring.
    • The spacer.
    NOTE: Note the number of throttle valve compensating rings before removal. The number of rings determines the transmission line pressure. Install the same number of rings that are removed in order to ensure the proper transmission line pressure. Some valve bodies DO NOT require these rings.
  5. Slightly push in the throttle valve while removing the locating pin from the down shift plug using a magnet. See Fig 5 .
  6. Remove the following throttle valve components from the valve body:
    • The down shift plug.
    • The throttle valve primary spring. See Fig 6 .
    • The throttle valve.
    • The secondary valve spring.
    • The throttle valve compensating ring(s).
  7. Clean all of the upper valve body components. Allow the components to air dry. Inspect all of the valves for cracks, scoring, or other damage. Replace as necessary. Inspect all of the valve springs for distortion or other damage. Replace as necessary.
  8. Inspect the valve bores for scoring or cracks. Replace as necessary. Inspect the free length and outer coil diameter of all of the front upper valve body springs using vernier calipers. If the measurements DO NOT fall within specifications, replace the springs as necessary. See FRONT UPPER VALVE BODY SPRING SPECIFICATIONS  table.
FRONT UPPER VALVE BODY SPRING SPECIFICATIONS

Spring Name (No.) (1) Diameter - In. (mm) Free Length - In. (mm)
Cut Back Valve Spring Coil (#4) .269 (6.85) .905 (23.00)
Secondary Regulator Valve Spring (#1) .681 (17.43) 2.804 (71.23)
Secondary Valve Spring (#2) (Throttle) (2) .337 (8.58) .757 (19.24)
Throttle Valve Primary Spring (#3) .429 (10.90) 1.557 (39.55)
(1) See Fig 7 .
(2) On Grand Vitara/Vitara, spring diameter is .282" (7.16 mm).
Fig 1: Removing Throttle Valve Keep Plate
G00293980Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing Cut Back Retainer
G00293981Courtesy of GENERAL MOTORS CORP.
Fig 3: Identifying Front Valve Body End Cover
G00293982Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing TV Cable Cam Components
G00293983Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing Throttle Valve Downshift Plug Locating Pin
G00293984Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing Throttle Valve Components
G00293985Courtesy of GENERAL MOTORS CORP.
Fig 7: Exploded View Of Front Upper Valve Body
G93J24892Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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