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Automatic Transmission Unit Disassembly

Reference: Automatic Transmission Assembly Dismounting and Remounting 

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: Identifying Torque Converter
    G04808632Courtesy of SUZUKI OF AMERICA CORP.
  2. Remove breather pipe (1) from transmission.
    Fig 2: Identifying Breather Pipe
    G04808633Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove output shaft speed sensor (1) and input shaft speed sensor (2).
    Fig 3: Identifying Input Shaft Speed Sensor
    G04808634Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the nut, the washer and manual select lever (1).
    Fig 4: Identifying Manual Select Lever
    G04808635Courtesy 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: Identifying Transmission Range Sensor
    G04808636Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove oil cooler pipes (1) from transmission.
    Fig 6: Identifying Oil Cooler Pipes
    G04808637Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove converter housing (1) by removing 10 bolts.
    Fig 7: Identifying Converter Housing
    G04808638Courtesy of SUZUKI OF AMERICA CORP.
  9. Remove transmission case adapter (1) by removing 8 bolts.
    Fig 8: Identifying Transmission Case Adapter
    G04808639Courtesy of SUZUKI OF AMERICA CORP.
  10. Remove oil pan bolts (1).
  11. Remove oil pan and oil pan gasket from transmission case.
    Fig 9: Identifying Oil Pan Bolts
    G04808640Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove the 4 magnets (1) and clean them to steel particles etc.
    Fig 10: Identifying Magnets
    G04808641Courtesy of SUZUKI OF AMERICA CORP.
  13. Remove oil strainer (1) from valve body assembly.
    Fig 11: Identifying Oil Strainer
    G04808642Courtesy of SUZUKI OF AMERICA CORP.
  14. Remove transmission fluid temperature sensors (1) from sensor clamps (2).
  15. Remove wire harness clamp (3).
  16. 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 12: Identifying Fluid Temperature Sensors & Harness Clamp
    G04808643Courtesy of SUZUKI OF AMERICA CORP.

    17) 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 13: Identifying Transmission Wire Connector
    G04808644Courtesy of SUZUKI OF AMERICA CORP.
  17. Remove spring plate (1) and manual shift lever spring (2).
  18. Remove valve body assembly (3) by removing 19 bolts.
    Fig 14: Identifying Spring Plate & Manual Shift Lever Spring
    G04808645Courtesy of SUZUKI OF AMERICA CORP.
  19. Remove check ball body (1) and spring (2).
    Fig 15: Identifying Check Ball Body & Spring
    G04808646Courtesy of SUZUKI OF AMERICA CORP.
  20. Remove transmission case gaskets (1).
    Fig 16: Identifying Transmission Case Gaskets
    G04808647Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove brake drum gaskets (1) from transmission case.
    Fig 17: Identifying Brake Drum Gaskets
    G04808648Courtesy of SUZUKI OF AMERICA CORP.
  22. 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.
  23. Remove direct clutch accumulator piston spring from transmission case.
    Fig 18: Identifying Direct Clutch Accumulator Piston
    G04808649Courtesy of SUZUKI OF AMERICA CORP.
  24. 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 19: Identifying Accumulator Piston
    G04808650Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove 2nd (No. 3) brake accumulator piston spring from transmission case.
  26. 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 20: Removing Reverse Clutch Accumulator Piston
    G04808651Courtesy of SUZUKI OF AMERICA CORP.
  27. Remove reverse clutch accumulator piston springs from transmission case.
  28. Remove forward clutch accumulator piston (1).
    Fig 21: Identifying Forward Clutch Accumulator Piston
    G04808652Courtesy of SUZUKI OF AMERICA CORP.
  29. Remove forward clutch accumulator piston springs from transmission case.
  30. Remove parking pawl bracket (1).
    Fig 22: Identifying Parking Pawl Bracket
    G04808653Courtesy of SUZUKI OF AMERICA CORP.
  31. Remove parking lock rod (2) from manual shift lever (1).
    Fig 23: Identifying Parking Lock Rod & Manual Shift Lever
    G04808654Courtesy of SUZUKI OF AMERICA CORP.
  32. Pull out parking pawl pin (1) to oil pump side and then remove parking lock pawl (2) and parking pawl spring (3).
    Fig 24: Identifying Parking Pawl Pin, Parking Lock Pawl & Parking Pawl Spring
    G04808655Courtesy of SUZUKI OF AMERICA CORP.
  33. 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 25: Identifying Sleeve Cover
      G04808656Courtesy of SUZUKI OF AMERICA CORP.
    2. Drive out manual shift lever pin (1) by using special tool and hammer.

      Special Tool 

      1. 09922-89810 
    3. Pull out manual shift shaft (2) from transmission case, and then remove manual shift lever (3) and sleeve cover (4).
      Fig 26: Identifying Manual Shift Lever Pin
      G04808657Courtesy of SUZUKI OF AMERICA CORP.
  34. Remove 2 manual shift shaft oil seals (1) from transmission case by using flat end rod or the like.
    Fig 27: Identifying Shaft Oil Seals
    G04808658Courtesy of SUZUKI OF AMERICA CORP.
  35. 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 28: Identifying Transmission Position
    G04808659Courtesy of SUZUKI OF AMERICA CORP.
  36. After removing oil pump bolts, remove oil pump assembly (1) by using special tool.

    Special Tool 

    1. 09927-66520 
    2. 09920-13120 
      Fig 29: Removing Oil Pump Assembly
      G04808660Courtesy of SUZUKI OF AMERICA CORP.
  37. Remove thrust bearing race No. 1 (1) and thrust bearing race No.10 (2) from oil pump assembly.
    Fig 30: Identifying Thrust Bearing Race No. 1 & Thrust Bearing Race
    G04808661Courtesy of SUZUKI OF AMERICA CORP.
  38. Remove clutch drum and input shaft assembly (1) from transmission case.
    Fig 31: Identifying Input Shaft Assembly
    G04808662Courtesy of SUZUKI OF AMERICA CORP.
  39. Remove clutch hub thrust washer (1) and thrust needle roller bearing No. 1 (2) and thrust needle roller bearing (3) from clutch drum and input shaft assembly.
    Fig 32: Identifying Clutch Hub Thrust Washer & Thrust Needle Roller Bearing
    G04808663Courtesy of SUZUKI OF AMERICA CORP.
  40. Remove one-way No. 2 clutch assembly (1) and clutch drum thrust washer No. 2 (2) from clutch drum & input shaft assembly.
    Fig 33: Identifying One-Way No. 2 Clutch Assembly & Clutch Drum Thrust Washer
    G04808664Courtesy of SUZUKI OF AMERICA CORP.
  41. Remove snap ring (1) by using flat end rod or the like.
    Fig 34: Removing Snap Ring
    G04808665Courtesy of SUZUKI OF AMERICA CORP.
  42. 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 35: Identifying Brake Cushion Plate
    G04808666Courtesy of SUZUKI OF AMERICA CORP.
  43. Remove snap ring (1) by using special tool.

    Special Tool 

    1. 09900-06108 
      Fig 36: Removing Snap Ring
      G04808667Courtesy of SUZUKI OF AMERICA CORP.
  44. Remove one-way No. 1 clutch assembly (1) and planetary carrier thrust washer No. 1 (2) from transmission case.
    Fig 37: Identifying One-Way No. 1 Clutch Assembly & Planetary Carrier Thrust Washer
    G04808668Courtesy of SUZUKI OF AMERICA CORP.
  45. Remove 2nd (No. 3) brake piston (1) including 2nd (No. 3) brake cylinder (2) from transmission case.
    Fig 38: Identifying Brake Cylinder
    G04808669Courtesy of SUZUKI OF AMERICA CORP.
  46. 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. 09927-66540 
      Fig 39: Removing Snap Ring
      G04808670Courtesy of SUZUKI OF AMERICA CORP.
  47. 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 40: Removing Brake Piston
    G04808671Courtesy of SUZUKI OF AMERICA CORP.
  48. Remove front planetary gear assembly (1) and one-way No. 1 clutch inner race (2) from transmission case.
    Fig 41: Identifying Front Planetary Gear Assembly & One-Way No. 1 Clutch Inner Race
    G04808672Courtesy of SUZUKI OF AMERICA CORP.
  49. Remove thrust needle roller bearing (1), thrust bearing race No. 3 (2) and planetary carrier thrust washer No. 2 (3) from transmission case.
    Fig 42: Identifying Thrust Needle Roller Bearing & Thrust Bearing Race
    G04808673Courtesy of SUZUKI OF AMERICA CORP.
  50. Remove front planetary ring gear assembly (1) and thrust needle roller bearing (2) from transmission case.
    Fig 43: Identifying Front Planetary Ring Gear Assembly
    G04808674Courtesy of SUZUKI OF AMERICA CORP.
  51. Remove snap ring (1) by using flat end rod or the like.
    Fig 44: Removing Snap Ring
    G04808675Courtesy of SUZUKI OF AMERICA CORP.
  52. Remove middle planetary ring gear (1) and front planetary ring gear flange (2) from front planetary ring gear.
    Fig 45: Identifying Middle Planetary Ring Gear & Front Planetary Ring Gear Flange
    G04808676Courtesy of SUZUKI OF AMERICA CORP.
  53. Remove No. 1 brake flange "F", No. 1 brake discs "D" and No. 1 brake plates "P" from transmission case.
    Fig 46: Identifying Brake Discs
    G04808677Courtesy of SUZUKI OF AMERICA CORP.
  54. Remove snap ring (1) by using flat end rod or the like.
    Fig 47: Removing Snap Ring
    G04808678Courtesy of SUZUKI OF AMERICA CORP.
  55. Remove No. 1 brake piston return spring (1) and No. 1 brake piston (2) from transmission case.
    Fig 48: Identifying Brake Piston Return Spring & Brake Piston
    G04808679Courtesy of SUZUKI OF AMERICA CORP.
  56. 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.
  57. Remove O-ring from No. 1 brake piston.
    Fig 49: Removing Brake Piston
    G04808680Courtesy of SUZUKI OF AMERICA CORP.
  58. Remove snap ring (1) by using flat end rod or the like.
    Fig 50: Removing Snap Ring
    G04808681Courtesy of SUZUKI OF AMERICA CORP.
  59. 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 51: Identifying Brake Discs
    G04808682Courtesy of SUZUKI OF AMERICA CORP.
  60. 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 52: Removing Brake Piston
    G04808683Courtesy of SUZUKI OF AMERICA CORP.
  61. Remove No. 2 brake piston (1) from No. 2 brake cylinder (2).
    Fig 53: Removing Brake Piston & Brake Cylinder
    G04808684Courtesy of SUZUKI OF AMERICA CORP.
  62. Remove middle planetary gear assembly (1), planetary sun gear (2) and thrust bearing race No. 4 (3) from transmission case.
    Fig 54: Identifying Middle Planetary Gear Assembly
    G04808685Courtesy of SUZUKI OF AMERICA CORP.
  63. Remove snap ring (1) by using special tool.

    Special Tool 

    1. 09900-06108 
    Fig 55: Removing Snap Ring
    G04808686Courtesy of SUZUKI OF AMERICA CORP.
  64. Remove intermediate shaft (1) and one-way No. 3 clutch assembly (2) from transmission case.
    Fig 56: Removing Intermediate Shaft
    G04808687Courtesy of SUZUKI OF AMERICA CORP.
  65. Remove one-way No. 3 clutch assembly (1) and one-way No. 3 clutch inner race (2) from intermediate shaft.
    Fig 57: Identifying One-Way Clutch Assembly & One-Way Clutch Inner Race
    G04808688Courtesy of SUZUKI OF AMERICA CORP.
  66. 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 58: Identifying Thrust Bearing Race, Thrust Needle Roller Bearing & Planetary Ring Gear Flange Assembly
    G04808689Courtesy of SUZUKI OF AMERICA CORP.
  67. Remove snap ring (1) by using flat end rod or the like.
    Fig 59: Removing Snap Ring
    G04808690Courtesy of SUZUKI OF AMERICA CORP.
  68. Remove rear planetary ring gear flange (1) from rear planetary ring gear (2).
    Fig 60: Identifying Rear Planetary Ring Gear Flange
    G04808691Courtesy of SUZUKI OF AMERICA CORP.
  69. Remove brake plate stopper spring (1) from transmission case.
    Fig 61: Identifying Brake Plate Stopper Spring
    G04808692Courtesy of SUZUKI OF AMERICA CORP.
  70. Remove 1st & reverse (No. 4) brake flange (1) from transmission case.
  71. Remove 1st & reverse (No. 4) brake plates "P" and 1st & reverse (No. 4) brake discs "D" from transmission case.
  72. Remove 1st & reverse (No. 4) brake flange "F" from transmission case.
    Fig 62: Identifying Brake Plates
    G04808693Courtesy of SUZUKI OF AMERICA CORP.
  73. Remove rear planetary gear assembly (1) from transmission case.
    Fig 63: Identifying Rear Planetary Gear Assembly
    G04808694Courtesy of SUZUKI OF AMERICA CORP.
  74. Remove thrust bearing race No.9 (1) and thrust needle roller bearing (2) from rear planetary gear assembly.
    Fig 64: Identifying Thrust Bearing Race & Thrust Needle Roller Bearing
    G04808695Courtesy of SUZUKI OF AMERICA CORP.
  75. Remove thrust needle roller bearing (1) from transmission case.
    Fig 65: Identifying Thrust Needle Roller Bearing
    G04808696Courtesy of SUZUKI OF AMERICA CORP.
  76. 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. 09922-86010 
      Fig 66: Removing Snap Ring
      G04808697Courtesy of SUZUKI OF AMERICA CORP.
  77. Remove 1st & reverse (No. 4) brake return spring (1).
    Fig 67: Identifying 1st Reverse (No. 4) Brake Return Spring
    G04808698Courtesy of SUZUKI OF AMERICA CORP.
  78. 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.
  79. Remove O-ring from 1st & reverse (No. 4) brake piston (1).
    Fig 68: Removing Brake Piston
    G04808699Courtesy of SUZUKI OF AMERICA CORP.
  80. Remove brake reaction sleeve (1) by using special tools.

    Special Tool 

    1. 09920-20310 
      Fig 69: Removing Brake Reaction Sleeve
      G04808700Courtesy of SUZUKI OF AMERICA CORP.
  81. Remove 1st & reverse brake inner piston (1) by using special tools.

    Special Tool 

    1. 09920-20310 
    Fig 70: Removing 1st Reverse Brake Inner Piston
    G04808701Courtesy of SUZUKI OF AMERICA CORP.
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