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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
    G04824883Courtesy of SUZUKI OF AMERICA CORP.
  2. Remove breather pipe (1) from transmission.
    Fig 2: Identifying Breather Pipe
    G04824884Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove output shaft speed sensor (1) and input shaft speed sensor (2).
    Fig 3: Identifying Input & Output Shaft Speed Sensor
    G04824885Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the nut, the washer and manual select lever (1).
    Fig 4: Identifying Nut, Washer & Manual Select Lever
    G04824886Courtesy 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 Lock Washer, Manual Shift Shaft Nut, Lock Washer & Grommet
    G04824887Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove oil cooler pipes (1) from transmission.
    Fig 6: Identifying Oil Cooler Pipes
    G04824888Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove converter housing (1) by removing 10 bolts.
    Fig 7: Identifying Converter Housing
    G04824889Courtesy of SUZUKI OF AMERICA CORP.
  9. Remove transmission case adapter (1) by removing 8 bolts.
    Fig 8: Identifying Transmission Case Adapter
    G04824890Courtesy 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
    G04824891Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove the 4 magnets (1) and clean them to steel particles etc.
    Fig 10: Identifying Magnets
    G04824892Courtesy of SUZUKI OF AMERICA CORP.
  13. Remove oil strainer (1) from valve body assembly.
    Fig 11: Identifying Oil Strainer
    G04824893Courtesy of SUZUKI OF AMERICA CORP.
  14. Remove transmission fluid temperature sensor (1) from sensor clamp (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 Transmission Fluid Temperature Sensor From Sensor Clamp
    G04824894Courtesy 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 sensor at narrow exist of case.

    Fig 13: Identifying Transmission Wire Connector & Bolt
    G04824895Courtesy of SUZUKI OF AMERICA CORP.
  18. Remove spring plate (1) and manual shift lever spring (2).
  19. Remove valve body assembly (3) by removing 19 bolts.
    Fig 14: Identifying Spring Plate & Manual Shift Lever Spring
    G04824896Courtesy of SUZUKI OF AMERICA CORP.
  20. Remove check ball body (1) and spring (2).
    Fig 15: Identifying Check Ball Body & Spring
    G04824897Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove transmission case gaskets (1).
    Fig 16: Identifying Transmission Case Gaskets
    G04824898Courtesy of SUZUKI OF AMERICA CORP.
  22. Remove brake drum gaskets (1) from transmission case.
    Fig 17: Identifying Brake Drum Gaskets
    G04824899Courtesy of SUZUKI OF AMERICA CORP.
  23. 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.

  24. Remove direct clutch accumulator piston spring from transmission case.
    Fig 18: Identifying Clutch Accumulator Piston
    G04824900Courtesy of SUZUKI OF AMERICA CORP.
  25. 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 Brake Accumulator Piston
    G04824901Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove 2nd (No.3) brake accumulator piston spring from transmission case.
  27. 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: Compressing Air Into Hole
    G04824902Courtesy of SUZUKI OF AMERICA CORP.
  28. Remove reverse clutch accumulator piston springs from transmission case.
  29. Remove forward clutch accumulator piston (1).
    Fig 21: Identifying Forward Clutch Accumulator Piston
    G04824903Courtesy of SUZUKI OF AMERICA CORP.
  30. Remove forward clutch accumulator piston springs from transmission case.
  31. Remove parking pawl bracket (1).
    Fig 22: Identifying Parking Pawl Bracket
    G04824904Courtesy of SUZUKI OF AMERICA CORP.
  32. Remove parking lock rod (2) from manual shift lever (1).
    Fig 23: Identifying Parking Lock Rod & Manual Shift Lever
    G04824905Courtesy of SUZUKI OF AMERICA CORP.
  33. 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 Lock Pawl & Parking Pawl Spring
    G04824906Courtesy of SUZUKI OF AMERICA CORP.
  34. 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: Tapping Sleeve Cover
      G04824907Courtesy 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 26: Tapping Manual Shift Lever Pin
      G04824908Courtesy of SUZUKI OF AMERICA CORP.
  35. Remove 2 manual shift shaft oil seals (1) from transmission case by using flat end rod or the like.
    Fig 27: Identifying Manual Shift Shaft Oil Seals
    G04824909Courtesy of SUZUKI OF AMERICA CORP.
  36. 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 Stand Size Specifications
    G04824910Courtesy of SUZUKI OF AMERICA CORP.
  37. 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
      G04824911Courtesy of SUZUKI OF AMERICA CORP.
  38. 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 & No. 10
    G04824912Courtesy of SUZUKI OF AMERICA CORP.
  39. Remove clutch drum and input shaft assembly (1) from transmission case.
    Fig 31: Identifying Clutch Drum & Input Shaft Assembly
    G04824913Courtesy of SUZUKI OF AMERICA CORP.
  40. 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 No.1
    G04824914Courtesy of SUZUKI OF AMERICA CORP.
  41. 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 No. 2
    G04824915Courtesy of SUZUKI OF AMERICA CORP.
  42. Remove snap ring (1) by using flat end rod or the like.
    Fig 34: Identifying Snap Ring
    G04824916Courtesy of SUZUKI OF AMERICA CORP.
  43. 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: Removing Brake Cushion Plate From Transmission Case
    G04824917Courtesy of SUZUKI OF AMERICA CORP.
  44. Remove snap ring (1) by using special tool.

    Special Tool 

    (A): 09900-06108 

    Fig 36: Identifying Snap Ring
    G04824918Courtesy of SUZUKI OF AMERICA CORP.
  45. 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 No. 1
    G04824919Courtesy of SUZUKI OF AMERICA CORP.
  46. Remove 2nd (No.3) brake piston (1) including 2nd (No.3) brake cylinder (2) from transmission case.
    Fig 38: Identifying Brake Piston & Cylinder
    G04824920Courtesy of SUZUKI OF AMERICA CORP.
  47. 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 39: Identifying Special Tool On Rake Return Spring
    G04824921Courtesy of SUZUKI OF AMERICA CORP.
  48. 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).
    Fig 40: Applying Compressed Air Into Oil Hole
    G04824922Courtesy of SUZUKI OF AMERICA CORP.
  49. 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
    G04824923Courtesy of SUZUKI OF AMERICA CORP.
  50. 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 No. 3 & Planetary Carrier Thrust Washer No. 2
    G04824924Courtesy of SUZUKI OF AMERICA CORP.
  51. Remove front planetary ring gear assembly (1) and thrust needle roller bearing (2) from transmission case.
    Fig 43: Identifying Front Planetary Ring Gear Assembly & Thrust Needle Roller Bearing
    G04824925Courtesy of SUZUKI OF AMERICA CORP.
  52. Remove snap ring (1) by using flat end rod or the like.
    Fig 44: Identifying Snap Ring With Flat Rod
    G04824926Courtesy of SUZUKI OF AMERICA CORP.
  53. 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
    G04824927Courtesy of SUZUKI OF AMERICA CORP.
  54. Remove No.1 brake flange "F", No.1 brake discs "D" and No.1 brake plates "P" from transmission case.
    Fig 46: Identifying Brake Plates "P" From Transmission Case
    G04824928Courtesy of SUZUKI OF AMERICA CORP.
  55. Remove snap ring (1) by using flat end rod or the like.
    Fig 47: Identifying Snap Ring
    G04824929Courtesy of SUZUKI OF AMERICA CORP.
  56. Remove No.1 brake piston return spring (1) and No.1 brake piston (2) from transmission case.
    Fig 48: Identifying No.1 Brake Piston Return Spring & No.1 Brake Piston
    G04824930Courtesy of SUZUKI OF AMERICA CORP.
  57. 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.
  58. Remove O-ring from No.1 brake piston.
    Fig 49: Applying Compressed Air Into Oil Hole
    G04824931Courtesy of SUZUKI OF AMERICA CORP.
  59. Remove snap ring (1) by using flat end rod or the like.
    Fig 50: Identifying Snap Ring
    G04824932Courtesy of SUZUKI OF AMERICA CORP.
  60. 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 Plates From Transmission Case
    G04824933Courtesy of SUZUKI OF AMERICA CORP.
  61. 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: Applying Compressed Air Into Oil Hole Of Transmission Case
    G04824934Courtesy of SUZUKI OF AMERICA CORP.
  62. Remove No.2 brake piston (1) from No.2 brake cylinder (2).
    Fig 53: Removing No. 2 Brake Piston & From No. 2 Brake Cylinder
    G04824935Courtesy of SUZUKI OF AMERICA CORP.
  63. 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, Planetary Sun Gear & Thrust Bearing Race No. 4
    G04824936Courtesy of SUZUKI OF AMERICA CORP.
  64. Remove snap ring (1) by using special tool.

    Special Tool 

    (A): 09900-06108 

    Fig 55: Identifying Snap Ring
    G04824937Courtesy of SUZUKI OF AMERICA CORP.
  65. Remove intermediate shaft (1) and one-way No.3 clutch assembly (2) from transmission case.
    Fig 56: Identifying Intermediate Shaft & One-Way No. 3 Clutch Assembly From Transmission Case
    G04824938Courtesy of SUZUKI OF AMERICA CORP.
  66. 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 No.3 Clutch Assembly & Inner Race From Intermediate Shaft
    G04824939Courtesy of SUZUKI OF AMERICA CORP.
  67. 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 No. 8 & Thrust Needle Roller Bearing
    G04824940Courtesy of SUZUKI OF AMERICA CORP.
  68. Remove snap ring (1) by using flat end rod or the like.
    Fig 59: Identifying Snap Ring
    G04824941Courtesy of SUZUKI OF AMERICA CORP.
  69. Remove rear planetary ring gear flange (1) from rear planetary ring gear (2).
    Fig 60: Identifying Rear Planetary Ring Gear Flange From Rear Planetary Ring Gear
    G04824942Courtesy of SUZUKI OF AMERICA CORP.
  70. Remove brake plate stopper spring (1) from transmission case.
    Fig 61: Identifying Brake Plate Stopper Spring
    G04824943Courtesy of SUZUKI OF AMERICA CORP.
  71. Remove 1st & reverse (No.4) brake flange (1) from transmission case.-145
  72. Remove 1st & reverse (No.4) brake plates "P" and 1st & reverse (No.4) brake discs "D" from transmission case.
  73. Remove 1st & reverse (No.4) brake flange "F" from transmission case.
    Fig 62: Identifying Brake Flange From Transmission Case
    G04824944Courtesy of SUZUKI OF AMERICA CORP.
  74. Remove rear planetary gear assembly (1) from transmission case.
    Fig 63: Identifying Rear Planetary Gear Assembly
    G04824945Courtesy of SUZUKI OF AMERICA CORP.
  75. Remove thrust bearing race No.9 (1) and thrust needle roller bearing (2) from rear planetary gear assembly.
    Fig 64: Identifying Thrust Bearing Race No. 9 & Thrust Needle Roller Bearing
    G04824946Courtesy of SUZUKI OF AMERICA CORP.
  76. Remove thrust needle roller bearing (1) from transmission case.
    Fig 65: Identifying Thrust Needle Roller Bearing
    G04824947Courtesy of SUZUKI OF AMERICA CORP.
  77. 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 66: Identifying Special Tool On Brake Return Spring
    G04824948Courtesy of SUZUKI OF AMERICA CORP.
  78. Remove 1st & reverse (No.4) brake return spring (1).
    Fig 67: Identifying Brake Return Spring
    G04824949Courtesy of SUZUKI OF AMERICA CORP.
  79. 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.
  80. Remove O-ring from 1st & reverse (No.4) brake piston (1).
    Fig 68: Applying Compressed Air Into Oil Hole
    G04824950Courtesy of SUZUKI OF AMERICA CORP.
  81. Remove brake reaction sleeve (1) by using special tools.

    Special Tool 

    (A): 09920-20310 

    Fig 69: Identifying Special Tool On Brake Reaction Sleeve
    G04824951Courtesy of SUZUKI OF AMERICA CORP.
  82. Remove 1st & reverse brake inner piston (1) by using special tools.

    Special Tool 

    (A): 09920-20310 

    Fig 70: Identifying Special Tool On Reverse Brake Inner Piston
    G04824952Courtesy of SUZUKI OF AMERICA CORP.
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