Precautions for Disassembly and Reassembly

As the automatic transmission consists of high precision components, the following cautions should be strictly observed when handling its parts in disassembly and reassembly.

Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during dismounting and remounting.
Select a clean place free from dust and dirt for overhauling.
Place a rubber mat on the work bench to protect parts from damage.
Work gloves or shop cloth should not be used. (Use a nylon cloth or a paper towel.)
When separating the case joint, do not pry with a screwdriver or such but tap with a plastic hammer lightly.
Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during disassembly and reassembly.
Wash the disassembled parts in ATF (Automatic Transmission Fluid) or kerosene (using care not to allow ATF or kerosene to get on your face, etc.) and confirm that each fluid passage is not clogged by blowing air into it. But use ATF to wash the disc, resin washers and rubber parts.
Replace each gasket, oil seal and O-ring with a new one.
Apply ATF to sliding or rotating parts before reassembly.
A new disc should be soaked in ATF at least 2 hours before use.
For service materials, do not use anything other than those listed below.

SERVICE MATERIALS SPECIFICATION

Service materials	Use
A/T FLUID: An equivalent of DEXRON ®-III	Applied to rotating part, sliding part and disc before assembly.
SUZUKI SUPER GREASE C (99000-25030)	Used to retain thrust bearing, bearing race, thrust washer and ball.

PART INSPECTION AND CORRECTION CHART

Part	Inspect for	Correction
Casted part, machined part	Small flaw, burr Deep or grooved flaw Clogged fluid passage Flaw on installing surface, residual gasket Crack	Remove with oil stone. Replace part. Clean with air or wire. Remove with oil stone or replace part. Replace part.
Bearing	Unsmooth rotation Streak, pitting, flaw, crack	Replace. Replace.
Bushing, thrust washer	Flaw, burr, wear, burning	Replace.
Oil seal, gasket	Flawed or hardened seal ring Worn seal ring on its periphery or side Piston seal ring, oil seal, gasket, etc.	Replace. Replace. Replace.
Gear	Flaw, burr Worn gear tooth	Replace. Replace.
Splined part	Burr, flaw, torsion	Correct with oil stone or replace.
Snap ring	Wear, flaw, distortion No interference	Replace. Replace.
Thread	Burr Damage	Replace. Replace.
Spring	Settling, sign of burning	Replace.
Clutch disc, brake disc	Wear, burning, distortion, damaged claw	Replace.
Clutch plate, brake plate	Wear, burning, distortion, damaged claw	Replace.
Sealing surface (where lip contacts)	Flaw, rough surface, stepped wear, foreign material	Replace.