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Automatic Transmission Unit Disassembly

CAUTION:
  • Keep component parts in group for each subassembly and avoid mixing them up.
  • Clean all parts with cleaning solvent thoroughly and air dry them.
  • Use kerosene or automatic transmission fluid as cleaning solvent.
  • Do not use wiping cloths or rags to clean or dry parts.
  • All oil passages should be blown out and checked to make sure that they are not obstructed.
  • Keep face and eyes away from solvent spray while air blowing parts.
  • Check mating surface for irregularities and remove them, if any, and clean it again.
  • Soak new clutch discs and brake discs in transmission fluid for at least 2 hours before assembly.
  • Replace all gaskets and O-rings with new ones.
  • Apply automatic transmission fluid to all O-rings.
  • When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
  • Replace oil seals that are removed and apply grease to their lips.
  • Before installing, be sure to apply automatic transmission fluid to sliding, rolling and thrusting surface of all component parts. Also after installation, make sure to check each part for proper operation.
  • Always use torque wrench when tightening bolts.
  1. Extract torque converter (1) from transmission.
    CAUTION: Remove torque converter as much straight as possible.
    Leaning it may cause to damage oil seal lip.
    Fig 1: Extracting Torque Converter
    G00761588Courtesy of SUZUKI OF AMERICA CORP.
  2. Remove breather pipe (1) from transmission.
    Fig 2: Removing Breather Pipe
    G00761589Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove output shaft speed sensor (1) and input shaft speed sensor (2).
    Fig 3: Removing Output & Input Shaft Speed Sensor
    G00761590Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the nut, the washer and manual select lever (1).
    Fig 4: Removing Manual Select Lever
    G00761591Courtesy of SUZUKI OF AMERICA CORP.
  5. Unbend bend parts of lock washer (1) and then remove manual shift shaft nut (2), lock washer and grommet.
  6. Remove transmission range sensor (3) by removing sensor bolt.
    Fig 5: Removing Transmission Range Sensor
    G00761592Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove oil cooler pipes (1) from transmission.
    Fig 6: Removing Oil Cooler Pipes
    G00761593Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove converter housing (1) by removing 10 bolts.
    Fig 7: Removing Converter Housing
    G00761594Courtesy of SUZUKI OF AMERICA CORP.
  9. For 2WD model, perform following procedure.
    1. Remove extension housing (1) by removing 6 bolts.
      Fig 8: Removing Extension Housing
      G00761595Courtesy of SUZUKI OF AMERICA CORP.
    2. Remove snap ring (1) from output shaft.
      Fig 9: Removing Snap Ring
      G00761596Courtesy of SUZUKI OF AMERICA CORP.
    3. Remove thrust needle roller bearing (1) and then remove bearing races (2).
      Fig 10: Removing Thrust Needle Roller Bearing
      G00761597Courtesy of SUZUKI OF AMERICA CORP.
    4. Remove extension housing dust deflector (1) using brass bar and hammer.
      Fig 11: Removing Extension Housing Dust
      G00761598Courtesy of SUZUKI OF AMERICA CORP.
    5. Remove oil seal (1) from extension housing by using special tool.

      Special tool 

      1. (A): 09913-50121
      Fig 12: Removing Oil Seal
      G00761599Courtesy of SUZUKI OF AMERICA CORP.
  10. For 4WD model, perform following procedure.
    1. Remove transmission case adapter (1) by removing 8 bolts.
      Fig 13: Removing Transmission Case Adapter
      G00761600Courtesy of SUZUKI OF AMERICA CORP.
    2. Remove transmission case adaptor oil seal (1) by using flat end rod or the like.
      Fig 14: Removing Transmission Case Adapter Oil Seal
      G00761601Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove oil pan bolts (1).
  12. Remove oil pan and oil pan gasket from transmission case.
    Fig 15: Removing Oil Pan & Gasket
    G00761602Courtesy of SUZUKI OF AMERICA CORP.
  13. Remove the 4 magnets (1) and clean them to steel particles etc.
    Fig 16: Removing Magnets
    G00761603Courtesy of SUZUKI OF AMERICA CORP.
  14. Remove oil strainer (1) from valve body assembly.
    Fig 17: Removing Oil Strainer
    G00761604Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove transmission fluid temperature sensors (1) from sensor clamps (2).
  16. Remove wire harness clamp (3).
  17. Disconnect the following connectors from shift solenoid-A, shift solenoid-B, shift solenoid-E, TCC solenoid, pressure control solenoid-A, pressure control solenoid-B and pressure control solenoid-C.
    Fig 18: Disconnecting Connectors From Shift Solenoid
    G00761605Courtesy of SUZUKI OF AMERICA CORP.
  18. After removing bolt (1) pull out transmission wire connector (2) from transmission case.
    CAUTION: When pulling transmission wire harness out of transmission case, take care not to damage connectors and transmission fluid temperature sensors at narrow exist of case.
    Fig 19: Pulling Out Transmission Wire Connector
    G00761606Courtesy of SUZUKI OF AMERICA CORP.
  19. Remove spring plate (1) and manual shift lever spring (2).
  20. Remove valve body assembly (3) by removing 19 bolts.
    Fig 20: Removing Valve Body
    G00761607Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove check bail body (1) and spring (2).
    Fig 21: Removing Check Bail Body & Spring
    G00761608Courtesy of SUZUKI OF AMERICA CORP.
  22. Remove transmission case gaskets (1).
    Fig 22: Removing Transmission Case Gaskets
    G00761609Courtesy of SUZUKI OF AMERICA CORP.
  23. Remove brake drum gaskets (1) from transmission case.
    Fig 23: Removing Brake Drum Gaskets
    G00761610Courtesy of SUZUKI OF AMERICA CORP.
  24. Remove direct clutch accumulator piston (1) by compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into hole (2).
    NOTE: Cover accumulator piston (1) with shop cloth while blowing because A/T fluid should be spattered.
  25. Remove direct clutch accumulator piston spring from transmission case.
    Fig 24: Removing Direct Clutch Accumulator Piston Spring
    G00761611Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove 2nd (No.3) brake accumulator piston (1) by compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into hole (2).
    NOTE: Cover accumulator piston (1) with shop cloth while blowing because A/T fluid should be spattered.
    Fig 25: Removing 2nd Brake Accumulator Piston
    G00761612Courtesy of SUZUKI OF AMERICA CORP.
  27. Remove 2nd (No.3) brake accumulator piston spring from transmission case.
  28. Remove reverse clutch accumulator piston (1) by compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into hole (2).
    NOTE: Cover accumulator piston (1) with shop cloth while blowing because A/T fluid should be spattered.
    Fig 26: Removing Reverse Clutch Accumulator Piston
    G00761613Courtesy of SUZUKI OF AMERICA CORP.
  29. Remove reverse clutch accumulator piston springs from transmission case.
  30. Remove forward clutch accumulator piston (1).
    Fig 27: Removing Forward Clutch Accumulator Piston
    G00761614Courtesy of SUZUKI OF AMERICA CORP.
  31. Remove forward clutch accumulator piston springs from transmission case.
  32. Remove parking pawl bracket (1).
    Fig 28: Removing Parking Pawl Bracket
    G00761615Courtesy of SUZUKI OF AMERICA CORP.
  33. Remove parking lock rod (2) from manual shift lever (1).
    Fig 29: Removing Parking Lock Rod
    G00761616Courtesy of SUZUKI OF AMERICA CORP.
  34. Pull out parking pawl pin (1) to oil pump side and then remove parking lock pawl (2) and parking pawl spring (3).
    Fig 30: Pulling Out Parking Pawl Pin
    G00761617Courtesy of SUZUKI OF AMERICA CORP.
  35. Remove manual shift shaft and lever as follows.
    1. Undo caulking of sleeve cover (1) by using flat end rod or the like and hammer.
      Fig 31: Removing Manual Shift Shaft & Lever
      G00761618Courtesy of SUZUKI OF AMERICA CORP.
    2. Drive out manual shift lever pin (1) by using special tool and hammer.

      Special tool 

      1. (A): 09922-89810
    3. Pull out manual shift shaft (2) from transmission case, and then remove manual shift lever (3) and sleeve cover (4).
      Fig 32: Removing Manual Shift Lever & Sleeve Cover
      G00761619Courtesy of SUZUKI OF AMERICA CORP.
  36. Remove 2 manual shift shaft oil seals (1) from transmission case by using flat end rod or the like.
    Fig 33: Removing Manual Shift Shaft Oil Seals
    G00761620Courtesy of SUZUKI OF AMERICA CORP.
  37. Place transmission on stand facing oil pump upward.
    NOTE:
    • To prevent transmission case from getting damaged, protect its contacting surface with stand by using shop cloth or the like.
    • A stand of such size as shown in the figure will facilitate work.
    Fig 34: Placing Transmission On Stand Facing Oil Pump Upward
    G00761621Courtesy of SUZUKI OF AMERICA CORP.
  38. After removing oil pump bolts, remove oil pump assembly (1) by using special tool.

    Special tool 

    1. (A): 09927-66520
    2. (B): 09920-13120
    Fig 35: Removing Oil Pump
    G00761622Courtesy of SUZUKI OF AMERICA CORP.
  39. Remove thrust bearing race No.1 (1) from oil pump assembly.
    Fig 36: Removing Thrust Bearing Race
    G00761623Courtesy of SUZUKI OF AMERICA CORP.
  40. Remove clutch drum and input shaft assembly (1) from transmission case.
    Fig 37: Removing Clutch Drum & Input Shaft
    G00761624Courtesy of SUZUKI OF AMERICA CORP.
  41. Remove clutch hub thrust washer (1) and thrust needle roller bearing (2) from clutch drum and input shaft assembly.
    Fig 38: Removing Clutch Hub Thrust Washer
    G00761625Courtesy of SUZUKI OF AMERICA CORP.
  42. Remove one-way No.2 clutch assembly (1) and clutch drum thrust washer No.2 (2) from clutch drum & input shaft assembly.
    Fig 39: Removing One-Way Clutch Assembly
    G00761626Courtesy of SUZUKI OF AMERICA CORP.
  43. Remove snap ring (1) by using flat end rod or the like.
    Fig 40: Removing Snap Ring
    G00761627Courtesy of SUZUKI OF AMERICA CORP.
  44. Remove 2nd (No.3) brake flange "F", 2nd (No.3) brake discs "D", 2nd (No.3) brake plates "P" and 2nd (No.3) brake cushion plate (1) from transmission case.
    Fig 41: Removing Brake Flange
    G00761628Courtesy of SUZUKI OF AMERICA CORP.
  45. Remove snap ring (1) by using special tool.

    Special tool 

    1. (A): 09900-06108
    Fig 42: Removing Snap Ring
    G00761629Courtesy of SUZUKI OF AMERICA CORP.
  46. Remove one-way No.1 clutch assembly (1) and planetary carrier thrust washer No.1 (2) from transmission case.
    Fig 43: Removing One-Way Clutch
    G00761630Courtesy of SUZUKI OF AMERICA CORP.
  47. Remove 2nd (No.3) brake piston (1) including 2nd (No.3) brake cylinder (2) from transmission case.
    Fig 44: Removing Brake Piston
    G00761631Courtesy of SUZUKI OF AMERICA CORP.
  48. Compress 2nd (No.3) brake return spring (1) until 2nd (No.3) 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 and then remove snap ring (2).
    CAUTION: Be careful when applying pressure, for overpressure will cause 2nd (No.3) brake return spring to deform.

    Special tool 

    1. (A): 09927-66540
    Fig 45: Compressing Brake Return Spring
    G00761632Courtesy of SUZUKI OF AMERICA CORP.
  49. Remove 2nd (No.3) brake piston from 2nd (No.3) brake cylinder (1) by applying compressed air (392 kPa, 4.0 kg/ cm2, 57 psi) into oil hole (2) of 2nd (No.3) brake cylinder (1) as shown in figure.
    Fig 46: Removing Brake Piston From Brake Cylinder
    G00761633Courtesy of SUZUKI OF AMERICA CORP.
  50. Remove front planetary gear assembly (1) and one-way No.1 clutch inner race (2) from transmission case.
    Fig 47: Removing Front Planetary Gear
    G00761634Courtesy of SUZUKI OF AMERICA CORP.
  51. Remove thrust needle roller bearing (1), thrust bearing race No.3 (2) and planetary carrier thrust washer No.2 (3) from transmission case.
    Fig 48: Removing Thrust Needle Roller Bearing
    G00761635Courtesy of SUZUKI OF AMERICA CORP.
  52. Remove front planetary ring gear assembly (1) and thrust needle roller bearing (2) from transmission case.
    Fig 49: Removing Front Planetary Ring Gear Assembly
    G00761636Courtesy of SUZUKI OF AMERICA CORP.
  53. Remove snap ring (1) by using flat end rod or the like.
    Fig 50: Removing Snap Ring
    G00761637Courtesy of SUZUKI OF AMERICA CORP.
  54. Remove middle planetary ring gear (1) and front planetary ring gear flange (2) from front planetary ring gear.
    Fig 51: Removing Middle Planetary Ring Gear
    G00761638Courtesy of SUZUKI OF AMERICA CORP.
  55. Remove No.1 brake flange "F", No.1 brake discs "D" and No.1 brake plates "P" from transmission case.
    Fig 52: Removing Brake Flange
    G00761639Courtesy of SUZUKI OF AMERICA CORP.
  56. Remove snap ring (1) by using flat end rod or the like.
    Fig 53: Removing Snap Ring
    G00761640Courtesy of SUZUKI OF AMERICA CORP.
  57. Remove No.1 brake piston return spring (1) and No.1 brake piston (2) from transmission case.
    Fig 54: Removing Brake Piston Return Spring
    G00761641Courtesy of SUZUKI OF AMERICA CORP.
  58. Remove No.1 brake piston from No.1 brake piston cylinder (1) by applying compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (2) of No. 1 brake piston cylinder (1) as shown in figure.
  59. Remove O-ring from No.1 brake piston.
    Fig 55: Removing O-Ring From Brake Piston
    G00761642Courtesy of SUZUKI OF AMERICA CORP.
  60. Remove snap ring (1) by using flat end rod or the like.
    Fig 56: Removing Snap Ring
    G00761643Courtesy of SUZUKI OF AMERICA CORP.
  61. Remove No.2 brake flange "F", No.2 brake piston return spring (1), No.2 brake discs "D" and No.2 brake plates "P" from transmission case.
    Fig 57: Removing Brake Flange
    G00761644Courtesy of SUZUKI OF AMERICA CORP.
  62. Remove No.2 brake cylinder including No.2 brake piston (1) by applying compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (2) of transmission case.
    Fig 58: Removing Brake Cylinder Including Brake Piston
    G00761645Courtesy of SUZUKI OF AMERICA CORP.
  63. Remove No.2 brake piston (1) from No.2 brake cylinder (2).
    Fig 59: Removing Brake Piston From Brake Cylinder
    G00761646Courtesy of SUZUKI OF AMERICA CORP.
  64. Remove middle planetary gear assembly (1), planetary sun gear (2) and thrust bearing race No. 4 (3) from transmission case.
    Fig 60: Removing Middle Planetary Gear
    G00761647Courtesy of SUZUKI OF AMERICA CORP.
  65. Remove snap ring (1) by using special tool.

    Special tool 

    1. (A): 09900-06108
    Fig 61: Removing Snap Ring
    G00761648Courtesy of SUZUKI OF AMERICA CORP.
  66. Remove intermediate shaft (1) and one-way No.3 clutch assembly (2) from transmission case.
    Fig 62: Removing Intermediate Shaft
    G00761649Courtesy of SUZUKI OF AMERICA CORP.
  67. Remove one-way No.3 clutch assembly (1) and one-way No.3 clutch inner race (2) from intermediate shaft.
    Fig 63: Removing One-Way Clutch Assembly
    G00761650Courtesy of SUZUKI OF AMERICA CORP.
  68. Remove thrust bearing race No.8 (1), thrust needle roller bearing (2), thrust bearing race No.7 (3) and planetary ring gear flange assembly (4) from intermediate shaft.
    Fig 64: Removing Thrust Bearing Race
    G00761651Courtesy of SUZUKI OF AMERICA CORP.
  69. Remove snap ring (1) by using flat end rod or the like.
    Fig 65: Removing Snap Ring
    G00761652Courtesy of SUZUKI OF AMERICA CORP.
  70. Remove rear planetary ring gear flange (1) from rear planetary ring gear (2).
    Fig 66: Removing Rear Planetary Ring Gear Flange
    G00761653Courtesy of SUZUKI OF AMERICA CORP.
  71. Remove brake plate stopper spring (1) from transmission case.
    Fig 67: Removing Brake Plate Stopper Spring
    G00761654Courtesy of SUZUKI OF AMERICA CORP.
  72. Remove 1st & reverse (No.4) brake flange (1) from transmission case.
  73. Remove 1st & reverse (No.4) brake plates "P" and 1st & reverse (No.4) brake discs "D" from transmission case.
  74. Remove 1st & reverse (No.4) brake flange "F" from transmission case.
    Fig 68: Removing 1st & Reverse Brake Flange
    G00761655Courtesy of SUZUKI OF AMERICA CORP.
  75. Remove rear planetary gear assembly (1) from transmission case.
    Fig 69: Removing Rear Planetary Gear
    G00761656Courtesy of SUZUKI OF AMERICA CORP.
  76. Remove thrust bearing race No.9 (1) and thrust needle roller bearing (2) from rear planetary gear assembly.
    Fig 70: Removing Thrust Bearing Race
    G00761657Courtesy of SUZUKI OF AMERICA CORP.
  77. Remove thrust needle roller bearing (1) from transmission case.
    Fig 71: Removing Thrust Needle Roller Bearing
    G00761658Courtesy of SUZUKI OF AMERICA CORP.
  78. Compress 1st & reverse (No.4) brake return spring (2) until the 1st & reverse (No.4) return spring is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool and then remove snap ring (1).
    CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 1st & reverse (No.4) return spring to deform.

    Special tool 

    1. (A): 09922-86010
    Fig 72: Compressing 1st & Reverse Brake Return Spring
    G00761659Courtesy of SUZUKI OF AMERICA CORP.
  79. Remove 1st & reverse (No.4) brake return spring (1).
    Fig 73: Removing 1st & Reverse Brake Return Spring
    G00761660Courtesy of SUZUKI OF AMERICA CORP.
  80. Remove 1st & reverse (No.4) brake piston (1) by applying compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole (2) of transmission case.
  81. Remove O-ring from 1st & reverse (No.4) brake piston (1).
    Fig 74: Removing O-Ring From 1st & Reverse
    G00761661Courtesy of SUZUKI OF AMERICA CORP.
  82. Remove brake reaction sleeve (1) by using special tools.

    Special tool 

    1. (A): 09920-20310
    Fig 75: Removing Brake Reaction Sleeve
    G00761662Courtesy of SUZUKI OF AMERICA CORP.
  83. Remove 1st & reverse brake inner piston (1) by using special tools.

    Special tool 

    1. (A): 09920-20310
    Fig 76: Removing 1st & Reverse Brake Inner Piston
    G00761663Courtesy of SUZUKI OF AMERICA CORP.
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