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Automatic Transmission Unit Disassembly

Reference: AUTOMATIC TRANSMISSION ASSEMBLY (WITH TRANSFER) 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
    G04722643Courtesy of SUZUKI OF AMERICA CORP.
  2. Remove breather pipe (1) from transmission.
    Fig 2: Identifying Breather Pipe
    G04722644Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove output shaft speed sensor (1) and input shaft speed sensor (2).
    Fig 3: Identifying Output Shaft & Input Shaft Speed Sensor
    G04722645Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the nut, the washer and manual select lever (1).
    Fig 4: Identifying Manual Select Lever
    G04722646Courtesy 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, Manual Shift Shaft Nut & Lock Washer
    G04722647Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove oil cooler pipes (1) from transmission.
    Fig 6: Identifying Oil Cooler Pipes
    G04722648Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove converter housing (1) by removing 10 bolts.
    Fig 7: Identifying Converter Housing
    G04722649Courtesy of SUZUKI OF AMERICA CORP.
  9. For 2WD model, perform following procedure.
    1. Remove extension housing (1) by removing 6 bolts.
      Fig 8: Identifying Extension Housing
      G04722650Courtesy of SUZUKI OF AMERICA CORP.
    2. Remove snap ring (1) from output shaft.
      Fig 9: Identifying Output Shaft Snap Ring
      G04722651Courtesy of SUZUKI OF AMERICA CORP.
    3. Remove thrust needle roller bearing (1) and then remove bearing races (2).
      Fig 10: Identifying Thrust Needle Roller Bearing & Bearing Races
      G04722652Courtesy of SUZUKI OF AMERICA CORP.
    4. Remove extension housing dust deflector (1) using brass bar and hammer.
      Fig 11: Identifying Extension Housing Dust Deflector
      G04722653Courtesy of SUZUKI OF AMERICA CORP.
    5. Remove oil seal (1) from extension housing by using special tool.

      Special Tool 

      (A): 09913-50121 

      Fig 12: Identifying Oil Seal & Special Tool
      G04722654Courtesy of SUZUKI OF AMERICA CORP.
  10. For 4WD model, perform following procedure.
    1. Remove transmission case adapter (1) by removing 8 bolts.
      Fig 13: Identifying Transmission Case Adapter
      G04722655Courtesy of SUZUKI OF AMERICA CORP.
    2. Remove transmission case adaptor oil seal (1) by using flat end rod or the like.
      Fig 14: Identifying Transmission Case Adaptor Oil Seal
      G04722656Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove oil pan bolts (1).
  12. Remove oil pan and oil pan gasket from transmission case.
    Fig 15: Identifying Oil Pan Bolts
    G04722657Courtesy of SUZUKI OF AMERICA CORP.
  13. Remove the 4 magnets (1) and clean them to steel particles etc.
    Fig 16: Identifying Magnets
    G04722658Courtesy of SUZUKI OF AMERICA CORP.
  14. Remove oil strainer (1) from valve body assembly.
    Fig 17: Identifying Oil Strainer
    G04722659Courtesy 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: Identifying Transmission Fluid Temperature Sensors, Sensor Clamps & Wire Harness Clamp
    G04722660Courtesy 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: Identifying Transmission Wire Connector And Bolt
    G04722661Courtesy 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: Identifying Spring Plate, Manual Shift Lever Spring & Valve Body Assembly
    G04722662Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove check ball body (1) and spring (2).
    Fig 21: Identifying Check Ball Body And Spring
    G04722663Courtesy of SUZUKI OF AMERICA CORP.
  22. Remove transmission case gaskets (1).
    Fig 22: Identifying Transmission Case Gaskets
    G04722664Courtesy of SUZUKI OF AMERICA CORP.
  23. Remove brake drum gaskets (1) from transmission case.
    Fig 23: Identifying Brake Drum Gaskets
    G04722665Courtesy 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: Identifying Direct Clutch Accumulator Piston & Hole
    G04722666Courtesy 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: Identifying Brake Accumulator Piston & Hole
    G04722667Courtesy 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: Identifying Reverse Clutch Accumulator Piston & Hole
    G04722668Courtesy of SUZUKI OF AMERICA CORP.
  29. Remove reverse clutch accumulator piston springs from transmission case.
  30. Remove forward clutch accumulator piston (1).
    Fig 27: Identifying Forward Clutch Accumulator Piston
    G04722669Courtesy of SUZUKI OF AMERICA CORP.
  31. Remove forward clutch accumulator piston springs from transmission case.
  32. Remove parking pawl bracket (1).
    Fig 28: Identifying Parking Pawl Bracket
    G04722670Courtesy of SUZUKI OF AMERICA CORP.
  33. Remove parking lock rod (2) from manual shift lever (1).
    Fig 29: Identifying Parking Lock Rod And Manual Shift Lever
    G04722671Courtesy 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: Identifying Parking Pawl Pin, Parking Lock Pawl And Parking Pawl Spring
    G04722672Courtesy 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: Identifying Sleeve Cover
      G04722673Courtesy of SUZUKI OF AMERICA CORP.
    2. Drive out manual shift lever pin (1) by using special tool and hammer.

      Special Tool 

      (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: Identifying Manual Shift Shaft, Sleeve Cover, Lever & Pin
      G04722674Courtesy 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: Identifying Manual Shift Shaft Oil Seals
    G04722675Courtesy 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: Identifying Stand Size Specifications
      G04722676Courtesy of SUZUKI OF AMERICA CORP.
  38. After removing oil pump bolts, remove oil pump assembly (1) by using special tool.

    Special Tool 

    (A): 09927-66520 

    (B): 09920-13120 

    Fig 35: Identifying Oil Pump Assembly & Special Tools
    G04722677Courtesy of SUZUKI OF AMERICA CORP.
  39. Remove thrust bearing race No.1 (1) from oil pump assembly.
    Fig 36: Identifying Thrust Bearing Race No.1
    G04722678Courtesy of SUZUKI OF AMERICA CORP.
  40. Remove clutch drum and input shaft assembly (1) from transmission case.
    Fig 37: Identifying Input Shaft Assembly
    G04722679Courtesy 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: Identifying Clutch Hub Thrust Washer And Thrust Needle Roller Bearing
    G04722680Courtesy 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: Identifying Clutch Assembly And Clutch Drum Thrust Washer
    G04722681Courtesy of SUZUKI OF AMERICA CORP.
  43. Remove snap ring (1) by using flat end rod or the like.
    Fig 40: Identifying Snap Ring
    G04722682Courtesy 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: Identifying Brake Flange, Brake Discs, Brake Plates & Brake Cushion Plate
    G04722683Courtesy of SUZUKI OF AMERICA CORP.
  45. Remove snap ring (1) by using special tool.

    Special Tool 

    (A): 09900-06108 

    Fig 42: Identifying Snap Ring & Special Tool
    G04722684Courtesy 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: Identifying Clutch Assembly And Planetary Carrier Thrust Washer
    G04722685Courtesy 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: Identifying Brake Piston & Brake Cylinder
    G04722686Courtesy 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 

    (A): 09927-66540 

    Fig 45: Identifying Snap Ring, Return Spring & Special Tool
    G04722687Courtesy 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: Identifying Brake Cylinder & Oil Hole
    G04722688Courtesy 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: Identifying Front Planetary Gear Assembly And Clutch Inner Race
    G04722689Courtesy 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: Identifying Thrust Needle Roller Bearing, Thrust Bearing Race And Planetary Carrier Thrust Washer
    G04722690Courtesy of SUZUKI OF AMERICA CORP.
  52. Remove front planetary ring gear assembly (1) and thrust needle roller bearing (2) from transmission case.
    Fig 49: Identifying Front Planetary Ring Gear Assembly And Thrust Needle Roller Bearing
    G04722691Courtesy of SUZUKI OF AMERICA CORP.
  53. Remove snap ring (1) by using flat end rod or the like.
    Fig 50: Identifying Snap Ring
    G04722692Courtesy 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: Identifying Middle Planetary Ring Gear And Front Planetary Ring Gear Flange
    G04722693Courtesy 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: Identifying Brake Flange, Brake Discs And Brake Plates
    G04722694Courtesy of SUZUKI OF AMERICA CORP.
  56. Remove snap ring (1) by using flat end rod or the like.
    Fig 53: Identifying Snap Ring
    G04722695Courtesy 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: Identifying Brake Piston Return Spring & Brake Piston
    G04722696Courtesy 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: Identifying Brake Piston Cylinder & Oil Hole
    G04722697Courtesy of SUZUKI OF AMERICA CORP.
  60. Remove snap ring (1) by using flat end rod or the like.
    Fig 56: Identifying Snap Ring
    G04722698Courtesy 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: Identifying Brake Flange, Brake Piston Return Spring, Brake Discs And Brake Plates
    G04722699Courtesy 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: Identifying Brake Piston & Oil Hole
    G04722700Courtesy of SUZUKI OF AMERICA CORP.
  63. Remove No.2 brake piston (1) from No.2 brake cylinder (2).
    Fig 59: Identifying Brake Piston And Brake Cylinder
    G04722701Courtesy 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: Identifying Middle Planetary Gear Assembly, Planetary Sun Gear And Thrust Bearing Race
    G04722702Courtesy of SUZUKI OF AMERICA CORP.
  65. Remove snap ring (1) by using special tool.

    Special Tool 

    (A) : 099000-06108 

    Fig 61: Identifying Snap Ring & Special Tool
    G04722703Courtesy of SUZUKI OF AMERICA CORP.
  66. Remove intermediate shaft (1) and one-way No.3 clutch assembly (2) from transmission case.
    Fig 62: Identifying Intermediate Shaft And Clutch Assembly
    G04722704Courtesy 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: Identifying Clutch Assembly And One-Way Clutch Inner Race
    G04722705Courtesy 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: Identifying Thrust Bearing Races, Thrust Needle Roller Bearing & Planetary Ring Gear Flange Assembly
    G04722706Courtesy of SUZUKI OF AMERICA CORP.
  69. Remove snap ring (1) by using flat end rod or the like.
    Fig 65: Identifying Snap Ring
    G04722707Courtesy of SUZUKI OF AMERICA CORP.
  70. Remove rear planetary ring gear flange (1) from rear planetary ring gear (2).
    Fig 66: Identifying Rear Planetary Ring Gear Flange & Rear Planetary Ring Gear
    G04722708Courtesy of SUZUKI OF AMERICA CORP.
  71. Remove brake plate stopper spring (1) from transmission case.
    Fig 67: Identifying Brake Plate Stopper Spring
    G04722709Courtesy 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: Identifying 1st & Reverse Brake Flange, Brake Plates & Brake Discs
    G04722710Courtesy of SUZUKI OF AMERICA CORP.
  75. Remove rear planetary gear assembly (1) from transmission case.
    Fig 69: Identifying Rear Planetary Gear Assembly
    G04722711Courtesy 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: Identifying Thrust Bearing Race And Thrust Needle Roller Bearing
    G04722712Courtesy of SUZUKI OF AMERICA CORP.
  77. Remove thrust needle roller bearing (1) from transmission case.
    Fig 71: Identifying Thrust Needle Roller Bearing
    G04722713Courtesy 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 

    (A): 09922-86010 

    Fig 72: Identifying Brake Return Spring, Snap Ring & Special Tool
    G04722714Courtesy of SUZUKI OF AMERICA CORP.
  79. Remove 1st & reverse (No.4) brake return spring (1).
    Fig 73: Identifying Brake Return Spring
    G04722715Courtesy 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: Identifying Brake Piston & Oil Hole
    G04722716Courtesy of SUZUKI OF AMERICA CORP.
  82. Remove brake reaction sleeve (1) by using special tools.

    Special Tool 

    (A): 09920-20310 

    Fig 75: Identifying Brake Reaction Sleeve & Special Tool
    G04722717Courtesy of SUZUKI OF AMERICA CORP.
  83. Remove 1st & reverse brake inner piston (1) by using special tools.

    Special Tool 

    (A): 09920-20310 

    Fig 76: Identifying Reverse Brake Inner Piston & Special Tool
    G04722718Courtesy of SUZUKI OF AMERICA CORP.
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