Automatic Transmission Unit Disassembly

Extract torque converter. And remove oil filler tube and dipstick.
CAUTION: Remove torque converter as much straight as possible. Leaning it may cause damage to oil seal lip.

Fig 1: Removing Torque Converter
Courtesy of SUZUKI OF AMERICA CORP.
Remove speed sensor (1).
Remove 6 adapter case fixing bolts and then remove adaptor case (2).
NOTE: Use care not to cause damage to oil seal.

Fig 2: Removing Speed Sensor
Courtesy of SUZUKI OF AMERICA CORP.
Remove gasket.
Remove shift switch (1).

Fig 3: Removing Shift Switch
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-ring (1) and then remove speed sensor rotor (2).
NOTE: Use care not to loose rotor stop key.

Fig 4: Removing C-Ring And Speed Sensor Rotor
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pump (5) by using puller (1).
NOTE: Use care not to cause damage to shaft bushing surface (2).
Remove bearing at the real of oil pump (5).
Remove O-ring from oil pump (5).
Holding input shaft (4) by hand, remove converter housing (3).

Fig 5: Removing Converter Housing
Courtesy of SUZUKI OF AMERICA CORP.
Check dimensions of overdrive (O/D) case surface and clutch cylinder surface for reassembly.
Remove overdrive (O/D) clutch assembly by holding input shaft (3).
Remove O/D case, bearing and bearing race.
NOTE: Confirm direction of bearing and bearing race for reassembly.

Fig 6: Removing O/D Case, Bearing And Bearing Race
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pan (1).
NOTE:
- Hold oil pan with oil pan side down to prevent foreign material in oil pan from entering valve body.
- If iron powder is found, it is possible that bearing, gear or clutch plate is worn.
Fig 7: Removing Oil Pan
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil tubes.
NOTE: Refer to figure for order of their removal.
Remove coupler from solenoid valve (1).

Fig 8: Removing Oil Tubes
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil strainer (1).
Remove valve body (2) mounting bolts as shown in the figure.

Fig 9: Removing Valve Body Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Lift valve body (1) and disconnect A/T throttle cable (3) from throttle cam (2). And remove valve body (1).
Disconnect throttle cable (3) from case (4).

Fig 10: Disconnecting Throttle Cable From Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove accumulator pistons (1) by blowing air into holes as shown in the figure.
NOTE: Hold accumulator piston (1) with shop cloth while blowing.

Fig 11: Removing Accumulator Pistons
Courtesy of SUZUKI OF AMERICA CORP.
Place transmission upright as shown in the figure.
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 12: Placing Transmission Upright
Courtesy of SUZUKI OF AMERICA CORP.
Check top surface level of forward clutch (2) against case (1) for reassembly.
Remove forward clutch.
NOTE: Confirm direction of bearing and bearing race for reassembly.

Fig 13: Removing Forward Clutch
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch (1).

Fig 14: Removing Direct Clutch
Courtesy of SUZUKI OF AMERICA CORP.
Remove parking rod (1) and parking pawl (2).

Fig 15: Removing Parking Rod And Parking Pawl
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2 bolts (1) from valve body side to remove center support.

Fig 16: Removing Center Support Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove center support assembly (1).

Fig 17: Removing Center Support Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining ring (1), planetary gear assembly and leaf spring.
NOTE:
- Use care not to cause damage to case when removing retaining ring.
- Confirm direction of bearing and bearing race for reassembly.
Fig 18: Removing Retaining Ring, Planetary Gear Assembly And Leaf Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse brake retainer (1).
Special tool

(A): 09926-98390

(B): 09926-98320

Fig 19: Removing Reverse Brake Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove brake applying cover (1).

Fig 20: Removing Brake Applying Cover
Courtesy of SUZUKI OF AMERICA CORP.
Remove rear action sleeve and reverse brake piston by blowing air into hole (1) with (2) hole closed.

Fig 21: Removing Rear Action Sleeve And Reverse Brake Piston
Courtesy of SUZUKI OF AMERICA CORP.
Undo caulking of sleeve cover (1) by using moderate stick (2) and move sleeve cover (1).

Fig 22: Undoing Caulking Of Sleeve Cover
Courtesy of SUZUKI OF AMERICA CORP.
Using a punch, drive out manual shift lever pin, pull out manual shift shaft (2) and remove manual shift lever (1). Then remove sleeve cover from manual shift lever (1).

Fig 23: Removing Manual Shift Lever Pin, Manual Shift Shaft And Manual Shift Lever
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal (1) from both sides of transmission case.

Fig 24: Removing Oil Seal From Both Sides Of Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.