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Home >> Suzuki >> 2004 >> XL-7 EX, 4WD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - A/T >> Repair Instructions >> Automatic Transmission Unit Assembly
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Automatic Transmission Unit Assembly

  1. After applying A/T fluid to new 4 O-rings (1) and then install O-rings to 1st & reverse (No.4) brake inner piston (2) and brake reaction sleeve (3).
  2. Install 1st & reverse (No.4) brake inner piston (2) to brake reaction sleeve (3).
    CAUTION: Do not twist or deviate O-rings (1) during installation.
    Fig 1: Installing 1st & Reverse Brake Inner Piston To Brake Reaction Sleeve
    G00762162Courtesy of SUZUKI OF AMERICA CORP.
  3. Install 1st & reverse (No.4) brake inner piston (1) including brake reaction sleeve (2) to transmission case.
    CAUTION: Do not twist or deviate O-rings (3) during installation.
    Fig 2: Install 1st & Reverse Brake Inner Piston To Transmission Case
    G00762163Courtesy of SUZUKI OF AMERICA CORP.
  4. After applying A/T fluid to new O-ring (1) and then install O-ring to 1st & reverse (No.4) brake piston (2).
  5. Install 1st & reverse (No.4) brake piston (2) to transmission case.
    CAUTION: Do not twist or deviate O-ring (1) during installation.
    Fig 3: Installing 1st & Reverse Brake Piston To Transmission Case
    G00762164Courtesy of SUZUKI OF AMERICA CORP.
  6. Place 1st & reverse (No.4) brake return spring (1) on 1st & reverse (No.4) brake piston (2).
    Fig 4: Placing 1st & Reverse Brake Return Spring
    G00762165Courtesy of SUZUKI OF AMERICA CORP.
  7. Place snap ring (1) on 1st & reverse (No.4) brake return spring and compress 1st & reverse (No.4) brake return spring (2) until the 1st & reverse (No.4) brake return spring is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool.
    CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 1st & reverse (No.4) brake return spring to deform.

    Special tool 

    1. (A): 09922-86010
  8. Install snap ring (1).
    Fig 5: Installing Snap Ring
    G00762166Courtesy of SUZUKI OF AMERICA CORP.
  9. Make sure 1st & reverse (No.4) brake piston and 1st & reverse (No.4) brake inner piston move smoothly when applying low pressure compressed air (392 kPa, 4.0 kg/cm2 , 57 psi) into oil hole of transmission case.
    Fig 6: Applying Low Pressure Compressed Air Into Oil Hole
    G00762167Courtesy of SUZUKI OF AMERICA CORP.
  10. Using vernier calipers, measure the level difference (length A) between the upper surface of the 1st & reverse (No.4) brake piston and the hitting surface of 1st & reverse (No.4) brake flange at the both end across a diameter, and calculate the average.
    NOTE:
    • 1st & reverse (No.4) brake piston must be installed tightly to the end face of transmission case.
    • Length A:

      32.68 - 33.42 mm (1.287 - 1.316 in.)

    Fig 7: Measuring Level Difference Between Upper Surface & Hitting Surface
    G00762168Courtesy of SUZUKI OF AMERICA CORP.
  11. Using vernier calipers, measure the thickness (length B) of the 1st & reverse (No.4) brake flanges, the 1st & reverse (No.4) brake plates and the 1st & reverse (No.4) brake discs altogether at the both end across a diameter, and calculate the average.

    Pack Clearance 

    1. 0.7 - 1.0 mm (0.028 - 0.039 in.)
    • Pack Clearance: Length A - Length B + 1.36 mm (0.0535 in.)

      Length B: 30.59 - 31.62 mm (1.204 - 1.244 in.)

  12. If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
    Fig 8: Available 1st & Reverse (No.4) Brake Flange Thickness (1 Of 2)
    G00762169Courtesy of SUZUKI OF AMERICA CORP.
    Fig 9: Available 1st & Reverse (No.4) Brake Flange Thickness (2 Of 2)
    G00762170Courtesy of SUZUKI OF AMERICA CORP.
  13. After applying A/T fluid to thrust needle roller bearing (1), install thrust needle roller bearing (1) to transmission case.
    Fig 10: Installing Thrust Needle Roller Bearing
    G00762171Courtesy of SUZUKI OF AMERICA CORP.
  14. After applying A/T fluid to thrust needle roller bearing (2) and thrust bearing race No.9 (1) and then install thrust needle roller bearing (2) and thrust bearing race No.9 (1) to rear planetary ring gear.
    Fig 11: Installing Thrust Needle Roller Bearing & Bearing Race
    G00762172Courtesy of SUZUKI OF AMERICA CORP.
  15. Install rear planetary gear assembly (1).
    Fig 12: Installing Rear Planetary Gear
    G00762173Courtesy of SUZUKI OF AMERICA CORP.
  16. Place rear planetary flange (1) on rear planetary ring gear (2).
    Fig 13: Placing Rear Planetary Flange On Rear Planetary Ring Gear
    G00762174Courtesy of SUZUKI OF AMERICA CORP.
  17. Install snap ring (1) by using flat end rod or the like.
    Fig 14: Installing Snap Ring
    G00762175Courtesy of SUZUKI OF AMERICA CORP.
  18. Install thrust bearing race No.8 (1), thrust needle roller bearing (2), thrust bearing race No.7 (3) and planetary ring gear flange assembly (4) to intermediate shaft.
    Fig 15: Installing Thrust Bearing Race
    G00762176Courtesy of SUZUKI OF AMERICA CORP.
  19. Install intermediate shaft (1) including planetary ring gear flange assembly (2) to transmission case.
    Fig 16: Installing Intermediate Shaft
    G00762177Courtesy of SUZUKI OF AMERICA CORP.
  20. Install 1st & reverse (No.4) brake flange "F", 1st & reverse (No.4) brake discs "D" and 1st & reverse (No.4) brake plates "P" in the following order.

    F - D - P - D - P - D - P - D - P - D - P - D - P - D

  21. Install 1st & reverse (No.4) brake flange (1) with flat side of flange facing to toward the upside.
    Fig 17: Installing 1st & Reverse Brake Flange
    G00762178Courtesy of SUZUKI OF AMERICA CORP.
  22. Install brake plate stopper spring (1) to transmission case.
    Fig 18: Installing Brake Plate Stopper Spring
    G00762179Courtesy of SUZUKI OF AMERICA CORP.
  23. Install one-way No.3 clutch assembly (1) including one-way No.3 clutch inner race (2) to transmission case.
    Fig 19: Installing One-Way Clutch
    G00762180Courtesy of SUZUKI OF AMERICA CORP.
  24. Install snap ring (1) by using special tool being sure not to align snap ring end gap with cut portion of transmission case.

    Special tool 

    1. (A): 09900-06108
    Fig 20: Installing Snap Ring
    G00762181Courtesy of SUZUKI OF AMERICA CORP.
  25. Install thrust bearing race No.4 (3) to middle planetary gear assembly (1).
  26. Install middle planetary gear assembly (1) including planetary sun gear (2) into intermediate shaft.
    Fig 21: Installing Middle Planetary Gear
    G00762182Courtesy of SUZUKI OF AMERICA CORP.
  27. After applying A/T fluid to new 2 O-rings (1) and then install O-rings to No.2 brake piston (2).
  28. Install No.2 brake piston (2) to No.2 brake cylinder (3).
    CAUTION: Do not twist or deviate O-ring during installation.
    Fig 22: Installing Brake Piston
    G00762183Courtesy of SUZUKI OF AMERICA CORP.
  29. Install No. 2 brake cylinder (2) including No.2 brake piston (1) to transmission case.
    Fig 23: Installing Brake Cylinder
    G00762184Courtesy of SUZUKI OF AMERICA CORP.
  30. Install No.2 brake piston return spring (1) with spring side of plate facing to No.2 brake disc side.
  31. Install No.2 brake discs "D" and No.2 brake plates "P" in the following order.

    P - D - P - D - P - D

  32. Install No.2 brake flange "F" with spring flange side of flange facing to No.2 brake disc side.
    Fig 24: Installing Brake Flange
    G00762185Courtesy of SUZUKI OF AMERICA CORP.
  33. Compress No.2 brake piston return spring until the No.2 brake flange is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool.
    CAUTION: Be careful when applying pressure, for overpressure will cause No.2 brake return spring to deform.

    Special tool 

    1. (A): 09927-66510
    2. (B): 09913-85210
    3. (C): 09920-13120
  34. Place snap ring on No.2 brake flange being sure not to align snap ring end gap with cut portion of transmission case.
    Fig 25: Placing Snap Ring On Brake Flange
    G00762186Courtesy of SUZUKI OF AMERICA CORP.
  35. After applying A/T fluid to new 2 O-rings (1) and then install O-rings to No.1 brake piston (2).
  36. Install No.1 brake piston (2) to No.1 brake cylinder (3).
    CAUTION: Do not twist or deviate O-ring during installation.
    Fig 26: Installing Brake Piston
    G00762187Courtesy of SUZUKI OF AMERICA CORP.
  37. Install No.1 brake cylinder (2) including No.1 brake piston (1) to transmission case.
  38. Place No.1 brake piston return spring (3) on No.1 brake piston (1).
    Fig 27: Placing Brake Piston Return Spring
    G00762188Courtesy of SUZUKI OF AMERICA CORP.
  39. Compress No.1 brake piston return spring until the No.1 brake piston return spring is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool.
    CAUTION: Be careful when applying pressure, for overpressure will cause plate section of No.1 brake piston return spring to deform.

    Special tool 

    1. (A): 09927-66530
    2. (B): 09913-85210
    3. (C): 09920-13120
  40. Place snap ring on No.1 brake piston being sure not to align snap ring end gap with cut portion transmission case.
    Fig 28: Placing Snap Ring On Brake Piston
    G00762189Courtesy of SUZUKI OF AMERICA CORP.
  41. Install middle planetary ring gear (1) and front planetary ring gear flange (2) onto front planetary ring gear.
    Fig 29: Installing Middle Planetary Ring Gear
    G00762190Courtesy of SUZUKI OF AMERICA CORP.
  42. Install snap ring (1) by using flat end rod or the like.
    Fig 30: Installing Snap Ring
    G00762191Courtesy of SUZUKI OF AMERICA CORP.
  43. After applying petroleum jelly to thrust needle roller bearing (1) so that thrust needle roller bearing does not fall off.
  44. Install front planetary ring gear (2) and thrust needle roller bearing (1) into intermediate shaft.
    Fig 31: Installing Front Planetary Ring Gear
    G00762192Courtesy of SUZUKI OF AMERICA CORP.
  45. Install thrust needle roller bearing (1) and thrust bearing race No.3 (2) onto front planetary ring gear.
    Fig 32: Installing Thrust Needle Roller Bearing
    G00762193Courtesy of SUZUKI OF AMERICA CORP.
  46. Fit planetary carrier thrust washer No.2 (1) to front planetary gear assembly (2) with petroleum jelly so that planetary carrier thrust washer No. 2 (1) does not fall off.
    NOTE: Make sure projection part of planetary carrier thrust washer No.2 fit into holes of front planetary gear assembly.
  47. Install front planetary gear assembly (2) and one-way No.1 clutch inner race (3) onto front planetary ring gear.
    NOTE: Make sure align front planetary gear assembly trenches (4) and one-way No.1 clutch inner race holes (5).
    Fig 33: Installing Front Planetary Gear
    G00762194Courtesy of SUZUKI OF AMERICA CORP.
  48. Install No.1 brake discs "D", No.1 brake plates "P" and No.1 brake flange "F" in the following order. P - D - P - D - P - D - F
    Fig 34: Installing Brake Discs
    G00762195Courtesy of SUZUKI OF AMERICA CORP.
  49. Using vernier calipers, measure the level difference (length A) between the upper surface of the No. 1 brake piston and the hitting surface of No. 1 brake flange at the both end across a diameter, and calculate the average.
    NOTE:
    • No.1 brake piston must be installed tightly to the end face of transmission case.
    • Length A:

      15.29 - 15.77 mm (0.602 - 0.628 in.)

    Fig 35: Measuring Level Difference Between Upper & Hitting Surface
    G00762196Courtesy of SUZUKI OF AMERICA CORP.
  50. Using vernier calipers, measure the thickness (length B) of the No.1 brake flanges, the No.1 brake plates and the No.1 brake discs altogether at the both end across a diameter, and calculate the average.

    Pack Clearance 

    1. 0.42 - 0.72 mm (0.017 - 0.028 in.)
    • Pack Clearance: Length A - Length B

      Length B: 14.72 - 15.12 mm (0.58 - 0.595 in.)

  51. If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
    Fig 36: Identifying Available No.1 Brake Flange Thickness Chart (1 Of 2)
    G00762197Courtesy of SUZUKI OF AMERICA CORP.
    Fig 37: Identifying Available No.1 Brake Flange Thickness Chart (2 Of 2)
    G00762198Courtesy of SUZUKI OF AMERICA CORP.
  52. Install one-way No.1 clutch assembly (1) and planetary carrier thrust washer No.1 (2) to transmission case.
    NOTE: Make sure projection part of planetary carrier thrust washer No.1 fit into holes of one-way No.1 clutch inner race.
    Fig 38: Installing One-Way Clutch
    G00762199Courtesy of SUZUKI OF AMERICA CORP.
  53. After applying A/T fluid to new 2 O-rings (1) and then install O-rings to 2nd (No.3) brake piston (2).
  54. Install 2nd (No.3) brake piston (2) to 2nd (No.3) brake cylinder (3).
    CAUTION: Do not twist or deviate O-ring during installation.
    Fig 39: Installing Brake Piston To Brake Cylinder
    G00762200Courtesy of SUZUKI OF AMERICA CORP.
  55. Place 2nd (No.3) brake piston return spring (1) on 2nd (No.3) brake piston.
  56. Compress 2nd (No.3) brake piston return spring (1) until the 2nd (No.3) brake piston return spring is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool.
    CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 2nd (No.3) brake return spring to deform.

    Special tool 

    1. (A): 09927-66540
  57. Place snap ring (2) on 2nd (No.3) brake piston return spring retainer being sure not to align snap ring end gap with spring retainer claw.
    Fig 40: Placing Snap Ring On Brake Piston Return Spring Retainer
    G00762201Courtesy of SUZUKI OF AMERICA CORP.
  58. Install 2nd (No.3) brake piston (1) including 2nd (No.3) brake cylinder (2) to transmission case.
    Fig 41: Installing Brake Piston & Brake Cylinder
    G00762202Courtesy of SUZUKI OF AMERICA CORP.
  59. Install snap ring (1) by using special tool being sure not to align snap ring end gap with cut portion of transmission case.

    Special tool 

    1. (A): 09900-06108
    Fig 42: Installing Snap Ring
    G00762203Courtesy of SUZUKI OF AMERICA CORP.
  60. Fit clutch hub thrust washer (1) to one-way No.2 clutch assembly (2) with petroleum jelly so that clutch hub thrust washer (1) does not fall off.
  61. Install clutch hub thrust washer (1) and one-way No.2 clutch assembly (2) to transmission case.
    NOTE: Make sure projection part of clutch hub thrust washer fit into holes of one-way No.2 clutch assembly.
    Fig 43: Installing Clutch Hub Thrust Washer & One-Way Clutch
    G00762204Courtesy of SUZUKI OF AMERICA CORP.
  62. Install 2nd (No.3) brake cushion plate (1), 2nd (No.3) brake plates "P" and 2nd (No.3) brake discs "D". P - D - P - D - P - D - P - D
  63. Install 2nd (No.3) brake flange "F".
    Fig 44: Installing Brake Flange
    G00762205Courtesy of SUZUKI OF AMERICA CORP.
  64. Install snap ring (1) by using flat end rod or the like being sure not to align snap ring end gap with cut portion of transmission case.
    Fig 45: Installing Snap Ring
    G00762206Courtesy of SUZUKI OF AMERICA CORP.
  65. Fit clutch drum thrust washer No.2 (1) to clutch drum and input shaft assembly with petroleum jelly so that clutch drum thrust washer No.2 (1) does not fall off.
    NOTE: Make sure projection part of clutch drum thrust washer No.2 fit into holes of reverse clutch hub.
  66. Install thrust needle roller bearing (2) to clutch drum and input shaft assembly.
    Fig 46: Installing Thrust Needle Roller Bearing
    G00762207Courtesy of SUZUKI OF AMERICA CORP.
  67. Install clutch drum and input shaft assembly (1) to transmission case.
    Fig 47: Installing Clutch Drum & Input Shaft
    G00762208Courtesy of SUZUKI OF AMERICA CORP.
  68. After applying petroleum jelly to thrust bearing race No.1 (1) so that bearing race does not fall off, install it to oil pump assembly.
    Fig 48: Installing Thrust Bearing Race To Oil Pump
    G00762209Courtesy of SUZUKI OF AMERICA CORP.
  69. After applying A/T fluid to new O-ring (1) and then install O-ring to oil pump assembly (2).
    Fig 49: Installing O-Ring To Oil Pump
    G00762210Courtesy of SUZUKI OF AMERICA CORP.
  70. Install oil pump assembly aligning bolt holes in transmission case with oil pump assembly.

    Apply seal packing to 10 oil pump bolts and tighten them by certain amount of torque at each time one after another till specified torque is attained.

    Tightening torque 

    1. Oil pump bolt (a): 21 N.m (2.1 kg-m, 15.0 lb-ft)
    2. "A": Sealant 99000-31230
    NOTE: Make sure input shaft rotates smoothly.
    Fig 50: Installing Oil Pump Aligning Bolt Holes
    G00762211Courtesy of SUZUKI OF AMERICA CORP.
  71. Install new 2 manual shift shaft oil seals (1) to transmission case by using special tools.

    Special tool 

    1. (A): 09917-98221
    2. (B): 09916-57330
    Fig 51: Installing New Manual Shift Shaft Oil Seals
    G00762212Courtesy of SUZUKI OF AMERICA CORP.
  72. Apply compressed air (392 kPa, 4.0 kg/cm2 , 57 psi) into oil holes indicated in the figure. If there is no noise, disassemble and check installation condition of parts.
    • When inspecting 1st & reverse (No.4) brake, check oil hole (8) closed.
    Fig 52: Applying Compressed Air Into Oil Holes
    G00762213Courtesy of SUZUKI OF AMERICA CORP.
  73. Install a new spacer (1) to manual shift lever (2).
  74. Install manual shift shaft (3) to transmission case through manual shift lever.
    Fig 53: Installing Manual Shift Shaft
    G00762214Courtesy of SUZUKI OF AMERICA CORP.
  75. Drive in manual shift lever pin (1) by using hammer.
    Fig 54: Driving In Manual Shift Lever Pin
    G00762215Courtesy of SUZUKI OF AMERICA CORP.
  76. Align hole in sleeve cover with dent in manual shift lever and caulk securely with pin punch (1). Then check that manual shift shaft turns smoothly.
    Fig 55: Caulk Securely With Pin Punch
    G00762216Courtesy of SUZUKI OF AMERICA CORP.
  77. Install parking lock pawl (2), parking pawl pin (1) and parking pawl spring (3).
    Fig 56: Installing Parking Lock Pawl
    G00762217Courtesy of SUZUKI OF AMERICA CORP.
  78. Connect parking lock rod (2) to manual shift lever (1) as shown in the figure.
    Fig 57: Connecting Parking Lock Rod To Manual Shift Lever
    G00762218Courtesy of SUZUKI OF AMERICA CORP.
  79. Install parking lock pawl bracket (1).

    Tighten parking pawl bracket bolts (2) to specified torque.

    Tightening torque 

    1. Parking pawl bracket bolt (a): 7.4 N.m (0.74 kg-m, 5.5 lb-ft)
    Fig 58: Installing Parking Lock Pawl Bracket
    G00762219Courtesy of SUZUKI OF AMERICA CORP.
  80. Turn manual shift lever (1) to "P" position, confirm that rear planetary ring gear (2) is correctly locked up by parking lock pawl (3).
    Fig 59: Turning Manuel Shift Lever
    G00762220Courtesy of SUZUKI OF AMERICA CORP.
  81. After applying A/T fluid to new O-rings and then install O-rings to accumulator pistons.
  82. Install springs to transmission case.
    Fig 60: Identifying Accumulator Piston Spring Specification Chart (1 Of 3)
    G00762221Courtesy of SUZUKI OF AMERICA CORP.
    Fig 61: Identifying Accumulator Piston Spring Specification Chart (2 Of 3)
    G00762222Courtesy of SUZUKI OF AMERICA CORP.
    Fig 62: Identifying Accumulator Piston Spring Specification Chart (3 Of 3)
    G00762223Courtesy of SUZUKI OF AMERICA CORP.
  83. Install spring (2) and check ball body (1) to transmission case.
    Fig 63: Installing Spring & Check Ball Body
    G00762224Courtesy of SUZUKI OF AMERICA CORP.
  84. Install new brake drum gaskets (1).
    Fig 64: Installing New Brake Drum Gaskets
    G00762225Courtesy of SUZUKI OF AMERICA CORP.
  85. Install new transmission case gaskets (1).
    Fig 65: Installing New Transmission Case Gaskets
    G00762226Courtesy of SUZUKI OF AMERICA CORP.
  86. Align the groove of manual valve with pin of lever (1).
  87. Install valve body assembly (2) by using bolts noting their length shown below.

    Tightening torque 

    1. Valve body bolt (a): 11 N.m (1.1 kg-m, 8.0 lb-ft)
    Fig 66: Identifying Valve Body Bolt Length Chart
    G00762227Courtesy of SUZUKI OF AMERICA CORP.
  88. Install spring plate (3) and manual shift lever spring (4).
    Fig 67: Installing Spring Plate
    G00762228Courtesy of SUZUKI OF AMERICA CORP.
  89. After applying A/T fluid to new O-ring and then install transmission wire connector (2).

    Tighten transmission wire connector bolt (1) to specified torque.

    Tightening torque 

    1. Transmission wire connector bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
    Fig 68: Installing Transmission Wire Connector
    G00762229Courtesy of SUZUKI OF AMERICA CORP.
  90. Install transmission fluid temperature sensors (1).
  91. Install clamp and bolts to specified torque.

    Tightening torque 

    1. Transmission fluid temperature sensor clamp bolt (a): 11 N.m (1.1 kg-m, 8.0 lb-ft)
    2. Transmission fluid temperature sensor clamp bolt (b): 10 N.m (1.0 kg-m, 7.0 lb-ft)
    Fig 69: Identifying Transmission Fluid Temperature Sensor Clamp Bolt Length Chart
    G00762230Courtesy of SUZUKI OF AMERICA CORP.
    Fig 70: Identifying Transmission Fluid Temperature Sensor Harness Color Chart
    G00762231Courtesy of SUZUKI OF AMERICA CORP.
  92. Connect pressure control solenoid-A connector (1), pressure control solenoid-B connector (2), shift solenoid-A connector (3), shift solenoid-B connector (4), shift solenoid-E connector (5), TCC solenoid connector (6) and pressure control solenoid-C connector (7) to each solenoid valve.
    Fig 71: Shift Solenoid Valve Harness Color Chart
    G00762233Courtesy of SUZUKI OF AMERICA CORP.
    Fig 72: Identifying Pressure Control Solenoid Connector
    G00762234Courtesy of SUZUKI OF AMERICA CORP.
    Fig 73: Identifying Transmission Fluid Temperature Sensors
    G00372163Courtesy of SUZUKI OF AMERICA CORP.
  93. After applying A/T fluid to new O-ring and then install O-ring to oil strainer.
  94. Install oil strainer (1) to valve body assembly. Tighten 4 oil strainer bolts to specified torque.

    Tightening torque 

    1. Oil strainer bolt (a): 10 N.m (1.0 kg-m, 7.0 lb-ft)
    Fig 74: Installing Oil Strainer
    G00762235Courtesy of SUZUKI OF AMERICA CORP.
  95. Install 4 transmission magnets (1).
    Fig 75: Installing Transmission Magnets
    G00762236Courtesy of SUZUKI OF AMERICA CORP.
  96. Install a new gasket to oil pan.
  97. Install oil pan to transmission case.

    Tighten 20 oil pan bolts (1) to specified torque.

    Tightening torque 

    1. Oil pan bolt (a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft)
  98. Install drain plug (2).

    Tighten drain plug to specified torque.

    Tightening torque 

    1. Drain plug (b): 20 N.m (2.0 kg-m, 14.5 lb-ft)
    Fig 76: Installing Drain Plug
    G00762237Courtesy of SUZUKI OF AMERICA CORP.
  99. For 2WD model, perform following procedure.
    1. Install thrust needle roller bearing (1) and thrust bearing races (2) to extension housing sub assembly.
    2. Install snap ring (3) to extension housing sub assembly by using special tool.

      Special tool 

      1. (A): 09920-76010
      Fig 77: Installing Snap Ring To Extension Housing Sub Assembly
      G00762238Courtesy of SUZUKI OF AMERICA CORP.
    3. Measure clearance between snap ring (1) and thrust bearing race (2) by using thickness gauge.

      If clearance is out of specification, select thrust bearing race with suitable thickness from among the list below and replace it.

      Between snap ring and race clearance 

      1. Standard: 0.05 - 0.33 mm (0.002 - 0.013 in.)
      Fig 78: Identifying Available Thrust Bearing Race Thickness Chart
      G00762239Courtesy of SUZUKI OF AMERICA CORP.
      Fig 79: Measuring Clearance Between Snap Ring & Thrust Bearing Race
      G00762240Courtesy of SUZUKI OF AMERICA CORP.
    4. Install new oil seal to automatic transmission extension housing by using special tool and hammer.

      Special tool 

      1. (A): 09925-15410
      Fig 80: Installing New Oil Seal To Automatic Transmission Extension Housing
      G00762241Courtesy of SUZUKI OF AMERICA CORP.
    5. Install extension housing dust deflector (1) by using special tool and hammer.

      Special tool 

      1. (A): 09926-96050
      Fig 81: Installing Extension Housing Dust Deflector
      G00762242Courtesy of SUZUKI OF AMERICA CORP.
    6. Apply sealant continuously to extension housing (1) mating surface as shown in figure.

      "A": Sealant 99000-31230 

    7. Install extension housing (1) to transmission case.

      Tighten 6 bolts to specified torque.

    NOTE: Make sure to use new extension housing bolts.

    Tightening torque 

    1. Extension housing bolt (a): 34 N.m (3.4 kg-m, 24.5 lb-ft)
    Fig 82: Identifying Extension Housing Bolt Length Chart
    G00762243Courtesy of SUZUKI OF AMERICA CORP.
    Fig 83: Installing Extension Housing To Transmission Case
    G00762244Courtesy of SUZUKI OF AMERICA CORP.
  100. For 4WD model, perform following procedure.
    1. Install new oil seal to transmission adapter case by using special tool and hammer.

      Special tool 

      1. (A): 09913-75520
      Fig 84: Installing New Oil Seal to Transmission Adapter Case
      G00762245Courtesy of SUZUKI OF AMERICA CORP.
    2. Apply sealant continuously to transmission case adapter sub assembly (1) mating surface as shown in figure.

      "A": Sealant 99000-31230 

      Fig 85: Applying Sealant Continuously To Transmission Case Adapter Sub
      G00762246Courtesy of SUZUKI OF AMERICA CORP.
    3. Install transmission case adapter sub assembly (1) to transmission case. Tighten 8 transmission case adapter sub assembly bolts to specified torque.
    NOTE: Make sure to use new transmission case adapter sub assembly bolts.

    Tightening torque 

    1. Transmission case adapter sub assembly bolt (a): 34 N.m (3.4 kg-m, 24.5 lb-ft)
    Fig 86: Identifying Transmission Case Adapter Sub Assembly Chart
    G00762247Courtesy of SUZUKI OF AMERICA CORP.
    Fig 87: Installing Transmission Case Adapter Sub
    G00762248Courtesy of SUZUKI OF AMERICA CORP.
  101. Clean threads of automatic transmission housing bolts and bolt holes of transmission case, install automatic transmission housing (1) to transmission case.

    Tighten 10 automatic transmission housing bolts to specified torque.

    NOTE: Make sure to use new converter housing bolts (2) and (3).

    Tightening torque 

    1. Automatic transmission housing bolt (a): 57 N.m (5.7 kg-m, 41.5 lb-ft)
    2. Automatic transmission housing bolt (b): 34 N.m (3.4 kg-m, 24.5 lb-ft)
    Fig 88: Installing Automatic Transmission Housing
    G00762249Courtesy of SUZUKI OF AMERICA CORP.
  102. After applying A/T fluid to new O-ring and then install automatic transmission breather pipe (1).
  103. Install automatic transmission breather hose.

    Tightening 2 automatic transmission breather pipe bolts to specified torque.

    Tightening torque 

    1. Automatic transmission breather pipe bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
    Fig 89: Installing Automatic Breather Hose
    G00762250Courtesy of SUZUKI OF AMERICA CORP.
  104. After applying A/T fluid to new O-rings and then install them to output shaft speed sensor (1) and input shaft speed sensor (2).
  105. Install output shaft speed sensor (1) and input shaft speed sensor (2).

    Tighten transmission speed sensor bolts to specified torque.

    Tightening torque 

    1. Transmission speed sensor bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
    Fig 90: Installing Output & Input Shaft Speed Sensor
    G00762251Courtesy of SUZUKI OF AMERICA CORP.
  106. Apply A/T fluid to new 4 union gaskets and then install oil cooler pipes (1).

    Tighten 2 oil cooler pipe union bolts to specified torque.

    Tightening torque 

    1. Oil cooler pipe union bolt (a): 25 N.m (2.5 kg-m, 18.0 lb-ft)
    Fig 91: Installing Oil Cooler Pipes
    G00762252Courtesy of SUZUKI OF AMERICA CORP.
  107. Install transmission range sensor (1) and tighten transmission range sensor bolt (4) temporarily.
  108. Install grommet, lock washer (2) and nut (3).

    Tighten nut to specified torque. After tightening it, bend claws of lock washer.

    Tightening torque 

    1. Manual shift shaft nut (a): 7 N.m (0.7 kg-m, 5.0 lb-ft)
  109. After turning manual lever shaft fully counterclockwise, turn it clockwise by 2 notches and set it to "N" range.
  110. With neutral reference line (5) and groove (6) in transmission range sensor aligned. Tighten transmission range sensor bolt (4) to specified torque.

    Tightening torque 

    1. Transmission range sensor bolt (b): 13 N.m (1.3 kg-m, 9.5 lb-ft)
    Fig 92: Tightening Transmission Range Sensor Bolt
    G00762253Courtesy of SUZUKI OF AMERICA CORP.
  111. Install manual select lever (1).

    Tighten manual select lever nut (2) to specified torque.

    Tightening torque 

    1. Manual select lever nut (a): 13 N.m (1.3 kg-m, 9.5 lb-ft)
    Fig 93: Installing Manual Select Lever
    G00762254Courtesy of SUZUKI OF AMERICA CORP.
  112. Install torque converter (1) to input shaft.
    CAUTION: Install torque converter, using care not to damage oil seal lip of oil pump.
    Fig 94: Installing Torque Converter To Input Shaft
    G00762255Courtesy of SUZUKI OF AMERICA CORP.
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