LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2005 >> Grand Vitara EX, RWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> 5A/T >> Repair Instructions >> Automatic Transmission Unit Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

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 (No 4) Brake Inner Piston To Brake Reaction Sleeve
    G04100065Courtesy 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: Installing 1St & Reverse (No 4) Brake Inner Piston
    G04100066Courtesy 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 O-Ring To 1St & Reverse (No 4) Brake Piston
    G04100067Courtesy 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 (No 4) Brake Return Spring On 1St & Reverse (No 4) Brake Piston
    G04100068Courtesy 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 

    (A): 09922-86010 

  8. Install snap ring (1).
    Fig 5: Installing Snap Ring
    G04100069Courtesy 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: Checking Smoothly Movement Of 1St & Reverse (No 4) Brake Piston And 1St & Reverse (No 4) Brake Inner Piston
    G04100070Courtesy 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: Checking Level Difference Between Upper Surface Of 1st & Reverse (No 4) Brake Piston And Hitting Surface Of 1st & Reverse (No 4) Brake Flange
    G04100071Courtesy 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 

    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.
    AVAILABLE 1ST & REVERSE (NO.4) BRAKE FLANGE THICKNESS SPECIFICATION

    Identification No. Thickness Identification No. Thickness
    0 0 mm (0 in.) 8 0.8 mm (0.032 in.)
    2 0.2 mm (0.008 in.) 10 1.0 mm (0.039 in.)
    4 0.4 mm (0.016 in.) 12 1.2 mm (0.047 in.)
    6 0.6 mm (0.024 in.) 14 1.4 mm (0.055 in.)
    Fig 8: Identifying Thickness Of 1St & Reverse (No 4) Brake Flanges
    G04100072Courtesy 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 9: Installing Thrust Needle Roller Bearing To Transmission Case
    G04100073Courtesy 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 10: Installing Thrust Needle Roller Bearing And Thrust Bearing Race No 9 To Rear Planetary Ring Gear
    G04100074Courtesy of SUZUKI OF AMERICA CORP.
  15. Install rear planetary gear assembly (1).
    Fig 11: Installing Rear Planetary Gear Assembly
    G04100075Courtesy of SUZUKI OF AMERICA CORP.
  16. Place rear planetary flange (1) on rear planetary ring gear (2).
    Fig 12: Placing Rear Planetary Flange On Rear Planetary Ring Gear
    G04100076Courtesy of SUZUKI OF AMERICA CORP.
  17. Install snap ring (1) by using flat end rod or the like.
    Fig 13: Installing Snap Ring
    G04100077Courtesy 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 14: Installing Thrust Bearing Race No 8 And Thrust Needle Roller Bearing
    G04100078Courtesy of SUZUKI OF AMERICA CORP.
  19. Install intermediate shaft (1) including planetary ring gear flange assembly (2) to transmission case.
    Fig 15: Installing Intermediate Shaft (1) Including Planetary Ring Gear Flange Assembly
    G04100079Courtesy 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 16: Installing 1St & Reverse (No 4) Brake Flange
    G04100080Courtesy of SUZUKI OF AMERICA CORP.
  22. Install brake plate stopper spring (1) to transmission case.
    Fig 17: Installing Brake Plate Stopper Spring To Transmission Case
    G04100081Courtesy 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 18: Installing One-Way No 3 Clutch Assembly
    G04100082Courtesy 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 

    (A): 09900-06108 

    Fig 19: Installing Snap Ring
    G04100083Courtesy 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 20: Installing Middle Planetary Gear Assembly
    G04100084Courtesy 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 21: Installing No 2 Brake Piston To No 2 Brake Cylinder
    G04100085Courtesy of SUZUKI OF AMERICA CORP.
  29. Install No.2 brake cylinder (2) including No.2 brake piston (1) to transmission case.
    Fig 22: Installing No 2 Brake Cylinder
    G04100086Courtesy 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 23: Installing No 2 Brake Flange "F" With Spring Flange Side Of Flange Facing To No 2 Brake Disc Side
    G04100087Courtesy 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 

    (A): 09927-66510 

    (B): 09913-85210 

    (C): 09920-13120 

  34. Place snap ring on No.2 brake flange being sure not to align snap ring end gap with cut portion transmission case.
    Fig 24: Compressing No 2 Brake Piston
    G04100088Courtesy 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 25: Installing No 1 Brake Piston To No 1 Brake Cylinder
    G04100089Courtesy 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 26: Placing No 1 Brake Piston Return Spring On No 1 Brake Piston
    G04100090Courtesy 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 

    (A): 09927-66530 

    (B): 09913-85210 

    (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 27: Compressing No 1 Brake Piston
    G04100091Courtesy 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 28: Installing Middle Planetary Ring Gear And Front Planetary Ring Gear Flange Onto Front Planetary Ring Gear
    G04100092Courtesy of SUZUKI OF AMERICA CORP.
  42. Install snap ring (1) by using flat end rod or the like.
    Fig 29: Installing Snap Ring
    G04100093Courtesy 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 30: Installing Front Planetary Ring Gear And Thrust Needle Roller Bearing Into Intermediate Shaft
    G04100094Courtesy 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 31: Installing Thrust Needle Roller Bearing And Thrust Bearing Race No 3 Onto Front Planetary Ring Gear
    G04100095Courtesy 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 32: Installing Front Planetary Gear Assembly And One-Way No 1 Clutch Inner Race
    G04100096Courtesy 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 33: Installing No 1 Brake Discs "D", No 1 Brake Plates "P" And No 1 Brake Flange "F"
    G04100097Courtesy 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 34: Checking Level Difference Between Upper Surface Of No 1 Brake Piston And Hitting Surface Of No 1 Brake Flange
    G04100098Courtesy 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 

    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.
    AVAILABLE NO 1 BRAKE FLANGE THICKNESS SPECIFICATION

    Identification No. Thickness Identification No. Thickness
    0 2.0 mm (0.079 in.) 2 2.4 mm (0.094 in.)
    1 2.2 mm (0.087 in.) 3 2.6 mm (0.102 in.)
    Fig 35: Identifying Thickness (Length B) Of No 1 Brake Flanges
    G04100099Courtesy 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 36: Installing One-Way No 1 Clutch Assembly And Planetary Carrier Thrust Washer No 1 To Transmission Case
    G04100100Courtesy 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 37: Installing 2Nd (No 3) Brake Piston To 2Nd (No 3) Brake Cylinder
    G04100101Courtesy 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 

    (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 38: Placing Snap Ring On 2Nd (No 3) Brake Piston Return Spring Retainer
    G04100102Courtesy of SUZUKI OF AMERICA CORP.
  58. Install 2nd (No.3) brake piston (1) including 2nd (No.3) brake cylinder (2) to transmission case.
    Fig 39: Installing 2Nd (No 3) Brake Piston
    G04100103Courtesy 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 

    (A): 09900-06108 

    Fig 40: Installing Snap Ring
    G04100104Courtesy 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 41: Installing Clutch Hub Thrust Washer And One-Way No 2 Clutch Assembly
    G04100105Courtesy 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 42: Installing 2Nd (No 3) Brake Flange "F"
    G04100106Courtesy 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 43: Installing Snap Ring
    G04100107Courtesy of SUZUKI OF AMERICA CORP.
  65. Fit clutch drum thrust washer No.2 (1) to clutch dram 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 dram and input shaft assembly.
    Fig 44: Installing Thrust Needle Roller Bearing To Clutch Dram And Input Shaft Assembly
    G04100108Courtesy of SUZUKI OF AMERICA CORP.
  67. Install clutch dram and input shaft assembly (1) to transmission case.
    Fig 45: Installing Clutch Dram And Input Shaft Assembly To Transmission Case
    G04100109Courtesy 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 46: Installing Thrust Bearing Race No 1
    G04100110Courtesy 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 47: Installing O-Ring To Oil Pump Assembly
    G04100111Courtesy 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 

    Oil pump bolt (a): 21 N.m (2.1 kg-m, 15.0 lb-ft) 

    "A": Sealant 99000-31230 

    NOTE: Make sure input shaft rotates smoothly.
    Fig 48: Installing Oil Pump Assembly
    G04100112Courtesy of SUZUKI OF AMERICA CORP.
  71. Install new 2 manual shift shaft oil seals (1) to transmission case by using special tools.

    Special tool 

    (A): 09917-98221 

    (B): 09916-57330 

    Fig 49: Installing Manual Shift Shaft Oil Seals To Transmission Case
    G04100113Courtesy 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 50: Identifying Clutches And Brake Oil Holes
    G04100114Courtesy 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 51: Installing New Spacer To Manual Shift Lever
    G04100115Courtesy of SUZUKI OF AMERICA CORP.
  75. Drive in manual shift lever pin (1) by using hammer.
    Fig 52: Installing Manual Shift Lever Pin
    G04100116Courtesy 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 53: Aligning Hole In Sleeve Cover With Dent In Manual Shift Lever
    G04100117Courtesy of SUZUKI OF AMERICA CORP.
  77. Install parking lock pawl (2), parking pawl pin (1) and parking pawl spring (3).
    Fig 54: Installing Parking Lock Pawl, Parking Pawl Pin And Parking Pawl Spring
    G04100118Courtesy of SUZUKI OF AMERICA CORP.
  78. Connect parking lock rod (2) to manual shift lever (1) as shown in the figure.
    Fig 55: Connecting Parking Lock Rod To Manual Shift Lever
    G04100119Courtesy of SUZUKI OF AMERICA CORP.
  79. Install parking lock pawl bracket (1).

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

    Tightening torque 

    Parking pawl bracket bolt (a): 7.4 N.m (0.74 kg-m, 5.5 lb-ft) 

    Fig 56: Installing Parking Lock Pawl Bracket
    G04100120Courtesy 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 57: Turning Manual Shift Lever To "P" Position
    G04100121Courtesy 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.
    ACCUMULATOR PISTON SPRING SPECIFICATION

    Accumulator spring Free length Outside diameter Identification painting
    Forward clutch accumulator(1) Inner 30.40 mm (1.197 in.) 11.40 mm (0.449 in.) Pink
    Outer 48.76 mm (1.920 in.) 16.60 mm (0.654 in.) Green
    Reverse clutch accumulator (2) Inner 44.0 mm (1.732 in.) 14.0 mm (0.551 in.) Yellow
    Outer 73.35 mm (2.888 in.) 19.90 mm (0.784 in.) Red
    2nd (No.3) brake accumulator (3) 64.5 mm (2.540 in.) 19.5 mm (0.768 in.) Orange
    Direct clutch accumulator (4) 62.0 mm (2.441 in.) 15.9 mm (0.626 in.) White
    Fig 58: Installing Springs To Transmission Case
    G04100122Courtesy of SUZUKI OF AMERICA CORP.
  83. Install spring (2) and check ball body (1) to transmission case.
    Fig 59: Installing Spring And Check Ball Body To Transmission Case
    G04100123Courtesy of SUZUKI OF AMERICA CORP.
  84. Install new brake drum gaskets (1).
    Fig 60: Installing New Brake Drum Gaskets
    G04100124Courtesy of SUZUKI OF AMERICA CORP.
  85. Install new transmission case gaskets (1).
    Fig 61: Installing New Transmission Case Gaskets
    G04100125Courtesy 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 

    Valve body bolt (a): 11 N.m (1.1 kg-m, 8.0 lb-ft) 

    Valve body bolt length 

    VALVE BODY BOLT LENGTH SPECIFICATION

    Bolt Length Pieces
    A 25.0 mm (0.984 in.) 16
    B 36.0 mm (1.417 in.) 3
  88. Install spring plate (3) and manual shift lever spring (4).
    Fig 62: Installing Spring Plate And Manual Shift Lever Spring
    G04100126Courtesy 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 

    Transmission wire connector bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft)

    Fig 63: Tightening Transmission Wire Connector Bolt
    G04100127Courtesy of SUZUKI OF AMERICA CORP.
  90. Install transmission fluid temperature sensors (1).
  91. Install clamp and bolts to specified torque.

    Tightening torque 

    Transmission fluid temperature sensor clamp bolt (a): 11 N.m (1.1 kg-m, 8.0 lb-ft) 

    Transmission fluid temperature sensor clamp bolt (b): 10 N.m (1.0 kg-m, 7.0 lb-ft) 

    TRANSMISSION FLUID TEMPERATURE SENSOR CLAMP BOLT LENGTH SPECIFICATION

    Bolt Length
    A 36.0 mm (1.417 in.)
    B 12.0 mm (0.472 in.)
    TRANSMISSION FLUID TEMPERATURE SENSOR HARNESS COLOR SPECIFICATION

    Fluid temperature sensor Color
    Transmission fluid temperature sensor A Orange
    Transmission fluid temperature sensor B Blue
    Fig 64: Tightening Transmission Fluid Temperature Sensor Clamp Bolt
    G04100128Courtesy 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.
    SHIFT SOLENOID VALVE HARNESS COLOR SPECIFICATION

    Solenoid valve Harness color
    Pressure control solenoid-A Green/Gray
    Pressure control solenoid-B Blue/Red
    Pressure control solenoid-C Purple/Yellow
    Shift solenoid-A White
    Shift solenoid-B Black
    Shift solenoid-E Light blue
    TCC solenoid Light green/Brown
    Fig 65: Checking Connect Pressure Control Solenoid Connectors
    G04100129Courtesy 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 

    Oil strainer bolt (a): 10 N.m (1.0 kg-m, 7.0 lb-ft) 

    Fig 66: Installing Oil Strainer To Valve Body Assembly
    G04100130Courtesy of SUZUKI OF AMERICA CORP.
  95. Install 4 transmission magnets (1).
    Fig 67: Installing Transmission Magnets
    G04100131Courtesy 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 

    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 

    Drain plug (b): 20 N.m (2.0 kg-m, 14.5 lb-ft) 

    Fig 68: Installing Oil Pan To Transmission Case
    G04100132Courtesy 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 

      (A): 09920-76010 

      Fig 69: Installing Snap Ring To Extension Housing Sub Assembly
      G04100133Courtesy 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 

      Standard: 0.05 - 0.33 mm (0.002 - 0.013 in.) 

      AVAILABLE THRUST BEARING RACE THICKNESS SPECIFICATION

      Identification No. Thickness Identification No. Thickness
      1 3.7 mm (0.146 in.) 4 4.0 mm (0.158 in.)
      2 3.8 mm (0.150 in.) 5 4.1 mm (0.161 in.)
      3 3.9 mm (0.154 in.) 6 4.2 mm (0.165 in.)
      Fig 70: Checking Clearance Between Snap Ring And Thrust Bearing Race
      G04100134Courtesy of SUZUKI OF AMERICA CORP.
    4. Install new oil seal to automatic transmission extension housing by using special tool and hammer.

      Special tool 

      (A): 09925-15410 

      Fig 71: Installing New Oil Seal To Automatic Transmission Extension Housing
      G04100135Courtesy of SUZUKI OF AMERICA CORP.
    5. Install extension housing dust deflector (1) by using special tool and hammer.

      Special tool 

      (A): 09926-96050 

      Fig 72: Installing Extension Housing Dust Deflector
      G04100136Courtesy 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 

      Extension housing bolt (a): 34 N.m (3.4 kg-m, 24.5 lb-ft) 

    EXTENSION HOUSING BOLT LENGTH SPECIFICATION

    Bolt Length
    B 45.0 mm (1.772 in.)
    C 35.0 mm (1.378 in.)
    Fig 73: Installing Extension Housing To Transmission Case
    G04100137Courtesy 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 

      (A): 09913-75520 

      Fig 74: Installing New Oil Seal To Transmission Adapter Case
      G04100138Courtesy 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 75: Applying Sealant Continuously To Transmission Case Adapter Sub Assembly Mating Surface
      G04100139Courtesy 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 

      Transmission case adapter sub assembly bolt (a): 34 N.m (3.4 kg-m, 24.5 lb-ft) 

    TRANSMISSION CASE ADAPTER SUB ASSEMBLY BOLT SPECIFICATION

    Bolt Length
    A 50.0 mm (1.969 in.)
    B 40.0 mm (1.575 in.)
    Fig 76: Installing Transmission Case Adapter Sub Assembly To Transmission Case
    G04100140Courtesy 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 

    Automatic transmission housing bolt (a): 57 N.m (5.7 kg-m, 41.5 lb-ft) 

    Automatic transmission housing bolt (b): 34 N.m (3.4 kg-m, 24.5 lb-ft) 

    Fig 77: Tightening Automatic Transmission Housing Bolt
    G04100141Courtesy 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 

    Automatic transmission breather pipe bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

    Fig 78: Tightening Automatic Transmission Breather Pipe Bolt
    G04100142Courtesy 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 

    Transmission speed sensor bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

    Fig 79: Tightening Transmission Speed Sensor Bolt
    G04100143Courtesy 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 

    Oil cooler pipe union bolt (a): 25 N.m (2.5 kg-m, 18.0 lb-ft) 

    Fig 80: Tightening Oil Cooler Pipe Union Bolts
    G04100144Courtesy 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 

    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 

    Transmission range sensor bolt (b): 13 N.m (1.3 kg-m, 9.5 lb-ft) 

    Fig 81: Tightening Transmission Range Sensor Bolt
    G04100145Courtesy of SUZUKI OF AMERICA CORP.
  111. Install manual select lever (1).

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

    Tightening torque 

    Manual select lever nut (a): 13 N.m (1.3 kg-m, 9.5 lb-ft) 

    Fig 82: Installing Manual Select Lever
    G04100146Courtesy 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 83: Installing Torque Converter To Input Shaft
G04100147Courtesy of SUZUKI OF AMERICA CORP.
scientia non olet · About LEMON Manuals