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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 >> Lower Valve Body Disassembly
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Lower 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 following components from the valve body:
    • The bypass valve. See Figure .
    • The bypass valve spring.
    • The check ball.
    • The valve dampening spring.
    • The valve body ball.
    • The ball valve spring.
  2. Remove the following lower valve body plate components from the valve body:
    • The bolts.
    • The gasket.
    • The plate. See Fig 1 .
  3. Remove the following TCC lock-up control valve plate components from the valve body:
    • The bolts.
    • The gasket.
    • The plate. See Fig 1 .
  4. Remove the following pressure relief valve components while depressing the retainer:
    • The bolt.
    • The retainer. See Fig 2 .
    • The spring.
    • The ball.
  5. Remove the following TCC solenoid components:
    • The bolt.
    • The solenoid. See Fig 3 .
    • The "O" Ring.
  6. Remove the following shift solenoid components:
    • The bolts.
    • The shift solenoids. See Fig 4 .
    • The gasket.
    • The low coast modulator valve spring.
    • The intercoast modulator valve spring.
    • The intermediate coast modulator valves.
  7. Remove the following TCC lock-up control sleeve components while depressing the sleeve:
    • The locating pin (using a magnet). See Fig 5 .
    • The sleeve.
    • The spring.
    NOTE: There are 4 step positions on the primary regulator valve sleeve. See Fig 6 . Note the position of the sleeve for assembly.
  8. Remove the primary regulator valve retainer using a magnet.
  9. Using a magnet, remove the following primary regulator valve components while depressing the sleeve:
    • The retainer.
    • The sleeve. See Fig 7 .
    • The plunger.
    • The spring.
    • The valve.
  10. Clean all upper valve body components. Allow the components to air dry. Inspect all valves and valve bores for cracks, scoring, or other damage. Replace as necessary. Inspect all valve springs for distortion or damage. Replace as necessary.
  11. Measure the free length and the outer coil diameter of all lower valve body springs using the vernier calipers. If any spring is not within the specifications as listed in the following table, replace as necessary. See LOWER VALVE BODY SPRING SPECIFICATIONS (GRAND VITARA/VITARA)  or LOWER VALVE BODY SPRING SPECIFICATIONS (SPORTAGE & TRACKER)  tables.
LOWER VALVE BODY SPRING SPECIFICATIONS (GRAND VITARA/VITARA)

Spring Name (No.)(1) Diameter - In. (mm) Free Length - In. (mm)
Ball Valve (#6) .437 (13.13) 1.265 (32.14)
Bypass Valve (#8) .544 (13.82) 1.138 (28.90)
Inter Coast Modulator Valve (#3)
Grand Vitara .394 (10.00) 1.008 (25.60)
Vitara .356 (9.04) 1.073 (27.26)
Low Coast Modulator Valve (#2) .394 (10.00) 1.395 (35.43)
Pressure Relief Valve (#5) .517 (13.13) 1.265 (32.14)
Primary Regulator Valve (#1) .536 (13.62) 1.980 (50.28)
TCC Lock-Up Control Valve (#4) .449 (11.40) 1.283 (32.60)
Valve Damping (#7) .195 (4.95) 0.787 (20.00)
(1) See Fig 8 and Fig 9 .
LOWER VALVE BODY SPRING SPECIFICATIONS (SPORTAGE & TRACKER)

Spring Name (No.) (1) Diameter - In. (mm) Free Length - In. (mm)
Ball Valve (#6) .437 (11.10) 1.265 (32.13)
Bypass Valve (#8) .544 (13.82) 1.312 (33.32)
Inter Coast Modulator Valve (#3) .394 (10.01) 1.395 (35.42)
Low Coast Modulator Valve (#2) .394 (10.01) 1.667 (42.34)
Pressure Relief Valve (#5) .517 (13.13) 1.501 (38.13)
Primary Regulator Valve (#1) .677 (17.20) 2.216 (56.30)
TCC Lock-Up Control Valve (#4) .445 (11.30) 1.362 (34.59)
Valve Damping (#7) .195 (4.95) .787 (20.00)
(1) See Fig 8 and Fig 9 .
Fig 1: Identifying Lower Valve Body Components
G00293990Courtesy of GENERAL MOTORS CORP.
Fig 2: Identifying Pressure Relief Valve Retainer
G00293991Courtesy of GENERAL MOTORS CORP.
Fig 3: Identifying TCC Solenoid
G00293992Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing Shift Solenoids
G00092184Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing TCC Lock-Up Control Sleeve Locating Pin
G00293993Courtesy of GENERAL MOTORS CORP.
Fig 6: Identifying Primary Regulator Valve Sleeve & Retainer
G00293994Courtesy of GENERAL MOTORS CORP.
Fig 7: Identifying Primary Regulator Valve Components
G00293995Courtesy of GENERAL MOTORS CORP.
Fig 8: Exploded View Of Lower Valve Body
G93E24889Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig 9: Identifying Lower Valve Body Check Ball Pin, Spring & Retainer Locations
G93H24890Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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