Automatic Transmission Unit Assembly

Reference:  BEARING AND RACE INSTALLATION DIAGRAM  

Reference:  AUTOMATIC TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING  

Reference:  AUTOMATIC TRANSMISSION UNIT DISASSEMBLY  

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: Identifying Brake Inner Piston & Brake Reaction Sleeve With O-Rings

   Courtesy 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: Identifying 1st & Reverse (No. 4) Brake Inner Piston & Brake Reaction Sleeve

   Courtesy 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: Identifying 1st & Reverse (No. 4) Brake Piston To Transmission Case

   Courtesy 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: Identifying Brake Return Spring On Brake Piston

   Courtesy 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: Identifying Special Tool On Snap Ring

   Courtesy 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: Applying Low Pressure Compressed Air Into Oil Hole Of Transmission Case

   Courtesy 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: Identifying Brake Piston & Hitting Surface Length Diameter

    Courtesy 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.
    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 Brake Flanges Length Diameter

    Courtesy of SUZUKI OF AMERICA CORP.
13. After applying A/T fluid to thrust needle roller bearing (1), install thrust bearing race No.9 (1) to transmission case.
    Fig 9: Identifying A/T Fluid To Thrust Needle Roller Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
14. After applying A/T fluid to thrust needle roller bearing (2) and thrust needle roller bearing (1) and then install thrust needle roller bearing (2) and thrust bearing race No.9 (1) to rear planetary ring gear.
    Fig 10: Identifying Thrust Needle Roller Bearing & Thrust Bearing Race No.9

    Courtesy of SUZUKI OF AMERICA CORP.
15. Install rear planetary gear assembly (1).
    Fig 11: Identifying Rear Planetary Gear Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
16. Place rear planetary flange (1) on rear planetary ring gear (2).
    Fig 12: Identifying Rear Planetary Flange

    Courtesy of SUZUKI OF AMERICA CORP.
17. Install snap ring (1) by using flat end rod or the like.
    Fig 13: Identifying Snap Ring

    Courtesy 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: Identifying Thrust Needle Roller Bearing & Planetary Ring Gear Flange Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
19. Install intermediate shaft (1) including planetary ring gear flange assembly (2) to transmission case.
    Fig 15: Identifying Intermediate Shaft & Planetary Ring Gear Flange Assembly

    Courtesy 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: Identifying 1st & Reverse Brake Flange & Brake Plates

    Courtesy of SUZUKI OF AMERICA CORP.
22. Install brake plate stopper spring (1) to transmission case.
    Fig 17: Identifying Brake Plate Stopper Spring

    Courtesy 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: Identifying One-Way No. 3 Clutch Assembly & Inner Race

    Courtesy 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

    Courtesy 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: Identifying Thrust Bearing Race No. 4 & Middle Planetary Gear Assembly

    Courtesy 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: Identifying No. 2 Brake Piston & Brake Cylinder

    Courtesy of SUZUKI OF AMERICA CORP.
29. Install No.2 brake cylinder (2) including No.2 brake piston (1) to transmission case.
    Fig 22: Identifying No. 2 Brake Cylinder & Brake Piston

    Courtesy 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: Identifying Brake Piston Return Spring, Brake Plate & Brake Discs

    Courtesy 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 

    1. 09927-66510 
    2. 09913-85210 
    3. 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: Identifying Special Tools

    Courtesy 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: Identifying No. 1 Brake Piston & Brake Cylinder

    Courtesy 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: Identifying No. 1 Brake Cylinder, Brake Piston Return Spring & Brake Piston

    Courtesy 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 

    1. 09927-66530 
    2. 09913-85210 
    3. 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: Identifying Special Tools

    Courtesy 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: Identifying Middle Planetary Ring Gear & Front Planetary Ring Gear Flange

    Courtesy of SUZUKI OF AMERICA CORP.
42. Install snap ring (1) by using flat end rod or the like.
    Fig 29: Installing Snap Ring

    Courtesy 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: Identifying Front Planetary Ring Gear & Thrust Needle Roller Bearing

    Courtesy 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: Identifying Thrust Needle Roller Bearing & Thrust Bearing Race No 3

    Courtesy 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: Identifying Front Planetary Gear Assembly & One-Way No. 1 Clutch Inner Race

    Courtesy 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: Identifying Brake Discs & Plates

    Courtesy 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: Identifying Difference Between Upper Surface Of No. 1 Brake Piston & Hitting Surface Of No. 1 Brake Flange

    Courtesy 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.
    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 Of No. 1 Brake Flanges & Plates

    Courtesy 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: Identifying One-Way No. 1 Clutch Assembly & Planetary Carrier Thrust Washer No. 1

    Courtesy 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: Identifying 2nd Brake Piston & Brake Cylinder

    Courtesy 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: Installing Snap Ring

    Courtesy 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: Identifying 2nd Brake Piston & Brake Cylinder

    Courtesy 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

    Courtesy 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: Identifying Clutch Hub Thrust Washer & One-Way No 2 Clutch Assembly

    Courtesy 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: Identifying Brake Cushion Plate, 2nd Brake Plates & Discs

    Courtesy 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

    Courtesy 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 No.1 (2) and thrust needle roller bearing No.2 (3) to clutch dram and input shaft assembly.
    Fig 44: Identifying Thrust Needle Roller Bearings

    Courtesy of SUZUKI OF AMERICA CORP.
67. Install clutch drum and input shaft assembly (1) to transmission case.
    Fig 45: Installing Clutch Drum & Input Shaft Assembly To Transmission Case

    Courtesy of SUZUKI OF AMERICA CORP.
68. After applying petroleum jelly to thrust bearing race No.1 (1) and thrust bearing race No.2 (2) so that bearing race does not fall off, install it to oil pump assembly.
    Fig 46: Identifying Thrust Bearing Races

    Courtesy of SUZUKI OF AMERICA CORP.
69. After applying A/T fluid to new O-ring (1), then install O-ring to oil pump assembly (2).
    Fig 47: Identifying O-Ring & Oil Pump Assembly

    Courtesy 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 99000-31230SUZUKI Bond No.1216B 

    NOTE: Make sure input shaft rotates smoothly.
    Fig 48: Identifying Oil Pump Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
71. Install new 2 manual shift shaft oil seals (1) to transmission case by using special tools.

    Special Tool 

    1. 09917-98221 
    2. 09916-57330 
       Fig 49: Installing Manual Shift Shaft Oil Seals To Transmission Case

       Courtesy 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 Direct, Reverse, Forward Clutch And 1st & Reverse (No. 4) Brake

      Courtesy 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 Manual Shift Shaft To Transmission Case

    Courtesy of SUZUKI OF AMERICA CORP.
75. Drive in manual shift lever pin (1) by using hammer.
    Fig 52: Installing Manual Shift Lever Pin

    Courtesy 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

    Courtesy of SUZUKI OF AMERICA CORP.
77. Install parking lock pawl (2), parking pawl pin (1) and parking pawl spring (3).
    Fig 54: Identifying Parking Lock Pawl, Pin & Spring

    Courtesy of SUZUKI OF AMERICA CORP.
78. Connect parking lock rod (2) to manual shift lever (1) as shown in the figure.
    Fig 55: Identifying Parking Lock Rod & Manual Shift Lever

    Courtesy 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: Identifying Parking Lock Pawl Bracket & Bolts

    Courtesy 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: Identifying Manual Shift Lever, Rear Planetary Ring Gear & Parking Lock Pawl

    Courtesy 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: Identifying Clutch Accumulator

    Courtesy of SUZUKI OF AMERICA CORP.
83. Install spring (2) and check ball body (1) to transmission case.
    Fig 59: Identifying Spring & Check Ball Body

    Courtesy of SUZUKI OF AMERICA CORP.
84. Install new brake drum gaskets (1).
    Fig 60: Identifying Brake Drum Gaskets

    Courtesy of SUZUKI OF AMERICA CORP.
85. Install new transmission case gaskets (1).
    Fig 61: Identifying Transmission Case Gaskets

    Courtesy 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 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: Identifying Valve Body Assembly & Bolts

    Courtesy 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: Identifying Transmission Wire Connector

    Courtesy of SUZUKI OF AMERICA CORP.
90. Install transmission fluid temperature sensor (1).
91. Install clamp bolt (a) and (b) (if removed) to specified torque.

    Tightening torque 

    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) 

    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
    
    

    Fluid temperature sensor	Color
    Transmission fluid temperature sensor	Blue

    Fig 64: Identifying Transmission Fluid Temperature Sensor & Clamp Bolts

    Courtesy 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
    
    

    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: Identifying Pressure Control Solenoid Connectors & Shift Solenoid Connectors

    Courtesy 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: Identifying Oil Strainer & Bolt

    Courtesy of SUZUKI OF AMERICA CORP.
95. Install 4 transmission magnets (1).
    Fig 67: Identifying Transmission Magnets

    Courtesy 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: Identifying Drain Plug

    Courtesy of SUZUKI OF AMERICA CORP.
99. Install new oil seal (if removed) to transmission adapter case by using special tool and hammer.

    Special Tool 

    (A): 09913-75520 

    Fig 69: Identifying Special Tool (09913-75520)

    Courtesy of SUZUKI OF AMERICA CORP.
100. Apply sealant continuously to transmission case adapter sub assembly (1) mating surface as shown in Fig 70.

     "A": Sealant 99000-31230SUZUKI Bond No.1216B 

     Fig 70: Identifying Transmission Case Adapter Sub Assembly

     Courtesy of SUZUKI OF AMERICA CORP.
101. 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 LENGTH
     
     

     Bolt	Length
     A	50.0 mm (1.969 in.)
     B	40.0 mm (1.575 in.)

     Fig 71: Identifying Transmission Case Adapter Sub Assembly Bolts

     Courtesy of SUZUKI OF AMERICA CORP.
102. 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 72: Identifying Automatic Transmission Housing Bolts

     Courtesy of SUZUKI OF AMERICA CORP.
103. After applying A/T fluid to new O-ring and then install automatic transmission breather pipe (1).
104. 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 73: Identifying Automatic Transmission Breather Pipe

     Courtesy of SUZUKI OF AMERICA CORP.
105. 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).
106. 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 74: Identifying Output Shaft Speed Sensor & Input Shaft Speed Sensor

     Courtesy of SUZUKI OF AMERICA CORP.
107. 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 75: Identifying Oil Cooler Pipes & Union Bolt

     Courtesy of SUZUKI OF AMERICA CORP.
108. Install transmission range sensor (1) and tighten transmission range sensor bolt (4) temporarily.
109. 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) 

110. After turning manual lever shaft fully counterclockwise, turn it clockwise by 2 notches and set it to "N" range.
111. 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 76: Identifying Transmission Range Sensor Bolt

     Courtesy of SUZUKI OF AMERICA CORP.
112. Install manual select lever (1).

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

     Tightening torque 

     Manual select lever nut a: 12.5 N.m (1.25 kg-m, 9.0 lb-ft) 

     Fig 77: Identifying Manual Select Lever & Nut

     Courtesy of SUZUKI OF AMERICA CORP.
113. Install torque converter (1) to input shaft.
     CAUTION:

     Install torque converter, using care not to damage oil seal lip of oil pump.

     Fig 78: Identifying Torque Converter

     Courtesy of SUZUKI OF AMERICA CORP.