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Automatic Transmission Unit Disassembly

WARNING: This page is about a different variant/trim than selected.

Reference: AUTOMATIC TRANSMISSION UNIT COMPONENTS 

Reference: AUTOMATIC TRANSMISSION ASSEMBLY COMPONENTS 

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
    G06500129Courtesy of SUZUKI OF AMERICA CORP.
  2. Remove breather pipe (1) from transmission.
    3. Fig 2: Identifying Breather Pipe
    G06500130Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove output shaft speed sensor (1) and input shaft speed sensor (2).
    Fig 3: Identifying Output And Input Shaft Speed Sensor
    G06500131Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the nut, the washer and manual select lever (1).
    5. Fig 4: Identifying Manual Select Lever
    G06500132Courtesy 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 And Transmission Range Sensor
    G06500133Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove oil cooler pipes (1) from transmission.
    Fig 6: Identifying Oil Cooler Pipes
    G06500134Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove converter housing (1) by removing 10 bolts.
    9. Fig 7: Identifying Converter Housing
    G06500135Courtesy of SUZUKI OF AMERICA CORP.
  9. Remove transmission case adapter (1) by removing 8 bolts.
    Fig 8: Identifying Transmission Case Adapter
    G06500136Courtesy 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
    G06500137Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove the 4 magnets (1) and clean them to steel particles etc.
    13. Fig 10: Identifying Magnets
    G06500138Courtesy of SUZUKI OF AMERICA CORP.
  13. Remove oil strainer (1) from valve body assembly.
    Fig 11: Identifying Oil Strainer
    G06500139Courtesy of SUZUKI OF AMERICA CORP.
  14. Remove transmission fluid temperature sensor (8).
  15. Remove wire harness clamp.
  16. Disconnect the following connectors from shift solenoid-A (1), shift solenoid-B (2), shift solenoid-E (3), TCC pressure control solenoid (4), pressure control solenoid-A (5), pressure control solenoid-B (6) and pressure control solenoid-C (7).
    Fig 12: Identifying Shift Solenoid, TCC Pressure Control Solenoid And Pressure Control Solenoid Connectors
    G06500140Courtesy of SUZUKI OF AMERICA CORP.
  17. After removing bolt (1) pull out solenoid connector (2) from transmission case.
    CAUTION: When pulling solenoid 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 Bolt And Solenoid Connector
    G06500141Courtesy of SUZUKI OF AMERICA CORP.
  18. Remove spring plate (1) and manual shift lever spring (2).
  19. Remove valve body assembly (3) by removing 20 bolts.
    Fig 14: Identifying Spring Plate, Manual Shift Lever Spring And Valve Body Assembly
    G06500142Courtesy of SUZUKI OF AMERICA CORP.
  20. Remove check ball body (1) and spring (2).
    Fig 15: Identifying Check Ball Body And Spring
    G06500143Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove transmission case gaskets (1).
    22. Fig 16: Identifying Transmission Case Gaskets
    G06500144Courtesy of SUZUKI OF AMERICA CORP.
  22. Remove brake drum gaskets (1) from transmission case.
    Fig 17: Identifying Brake Drum Gaskets
    G06500145Courtesy of SUZUKI OF AMERICA CORP.
  23. Remove direct clutch accumulator piston (1) by compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) into hole (2).
    NOTE: Cover accumulator piston (1) with nylon cloth while blowing because A/T fluid should be spattered.
  24. Remove direct clutch accumulator piston spring from transmission case.
    Fig 18: Removing Direct Clutch Accumulator Piston Using Compressed Air
    G06500146Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove 2nd (No. 3) brake accumulator piston (1) by compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) into hole (2).
    NOTE: Cover accumulator piston (1) with nylon cloth while blowing because A/T fluid should be spattered.
    Fig 19: Removing 2nd Brake Accumulator Piston Using Compressed Air
    G06500147Courtesy 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 kgf/cm2 , 57 psi) into hole (2).
    NOTE: Cover accumulator piston (1) with nylon cloth while blowing because A/T fluid should be spattered.
    Fig 20: Removing Reverse Clutch Accumulator Piston Using Compressed Air
    G06500148Courtesy 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
    G06500149Courtesy 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
    G06500150Courtesy of SUZUKI OF AMERICA CORP.
  32. Remove parking lock rod (2) from manual shift lever (1).
    Fig 23: Identifying Parking Lock Rod And Manual Shift Lever
    G06500151Courtesy 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 Pawl Pin, Parking Lock Pawl And Parking Pawl Spring
    G06500152Courtesy 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.
      2. Fig 25: Removing Sleeve Cover
      G06500153Courtesy 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: Driving Out Manual Shift Lever Pin
      G06500154Courtesy 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: Removing Manual Shift Shaft Oil Seals
    G06500155Courtesy 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 nylon cloth or the like.
    • A stand of such size as shown in figure will facilitate work.
      Fig 28: Identifying Stand Dimensions
      G06500156Courtesy of SUZUKI OF AMERICA CORP.
  37. After removing oil pump bolts, remove oil pump assembly (1) by using special tool.

    Special Tool 

    (A): 09927-66520 

    (B): 09920-13120 

    Fig 29: Removing Oil Pump Assembly
    G06500157Courtesy of SUZUKI OF AMERICA CORP.
  38. Remove thrust bearing race No. 1 (1) and thrust bearing race No. 10 (2) from oil pump assembly.
    39. Fig 30: Identifying Thrust Bearing Race No. 1 And No. 10
    G06500158Courtesy of SUZUKI OF AMERICA CORP.
  39. Remove clutch drum and input shaft assembly (1) from transmission case.
    Fig 31: Removing Clutch Drum And Input Shaft Assembly
    G06500159Courtesy 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 And Roller Bearing
    G06500160Courtesy 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 And Clutch Drum Thrust Washer No. 2
    G06500161Courtesy of SUZUKI OF AMERICA CORP.
  42. Remove snap ring (1) by using flat end rod or the like.
    Fig 34: Removing Snap Ring
    G06500162Courtesy 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: Identifying 2nd Brake Flange, Brake Discs, Brake Plates And Brake Cushion Plate
    G06500163Courtesy of SUZUKI OF AMERICA CORP.
  44. Remove snap ring (1) by using special tool.

    Special Tool 

    (A): 09900-06108 

    Fig 36: Removing Snap Ring
    G06500164Courtesy 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 And Planetary Carrier Thrust Washer No. 1
    G06500165Courtesy 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 2nd Brake Piston And Brake Cylinder
    G06500166Courtesy 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: Removing Snap Ring
    G06500167Courtesy 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 kgf/cm2 , 57 psi) into oil hole (2) of 2nd (No. 3) brake cylinder (1) as shown in figure.
    Fig 40: Removing 2nd Brake Piston Using Compressed Air
    G06500168Courtesy 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 And One-Way No. 1 Clutch Inner Race
    G06500169Courtesy 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 And Planetary Carrier Thrust Washer No. 2
    G06500170Courtesy of SUZUKI OF AMERICA CORP.
  51. Remove front planetary ring gear assembly (1) and thrust needle roller bearing (2) from transmission case.
    52. Fig 43: Identifying Front Planetary Ring Gear Assembly And Thrust Needle Roller Bearing
    G06500171Courtesy of SUZUKI OF AMERICA CORP.
  52. Remove snap ring (1) by using flat end rod or the like.
    Fig 44: Removing Snap Ring
    G06500172Courtesy 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 And Front Planetary Ring Gear Flange
    G06500173Courtesy 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.
    55. Fig 46: Identifying No. 1 Brake Flange, Brake Discs And Brake Plates
    G06500174Courtesy of SUZUKI OF AMERICA CORP.
  55. Remove snap ring (1) by using flat end rod or the like.
    Fig 47: Removing Snap Ring
    G06500175Courtesy 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: Removing No. 1 Brake Piston Return Spring And No. 1 Brake Piston
    G06500176Courtesy 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 kgf/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: Removing No. 1 Brake Piston Using Compressed Air
    G06500177Courtesy of SUZUKI OF AMERICA CORP.
  59. Remove snap ring (1) by using flat end rod or the like.
    Fig 50: Removing Snap Ring
    G06500178Courtesy 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 No. 2 Brake Flange, Brake Piston Return Spring, Brake Discs And Brake Plates
    G06500179Courtesy 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 kgf/cm2 , 57 psi) into oil hole (2) of transmission case.
    Fig 52: Removing No. 2 Brake Cylinder With No. 2 Brake Piston Using Compressed Air
    G06500180Courtesy of SUZUKI OF AMERICA CORP.
  62. Remove No. 2 brake piston (1) from No. 2 brake cylinder (2).
    Fig 53: Identifying No. 2 Brake Piston And No. 2 Brake Cylinder
    G06500181Courtesy 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 And Thrust Bearing Race No. 4
    G06500182Courtesy of SUZUKI OF AMERICA CORP.
  64. Remove snap ring (1) by using special tool.

    Special Tool 

    (A): 09900-06108 

    Fig 55: Removing Snap Ring
    G06500183Courtesy of SUZUKI OF AMERICA CORP.
  65. Remove intermediate shaft (1) and one-way No. 3 clutch assembly (2) from transmission case.
    Fig 56: Removing Intermediate Shaft And One-Way No. 3 Clutch Assembly
    G06500184Courtesy 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 And One-Way No. 3 Clutch Inner Race
    G06500185Courtesy 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 And Thrust Bearing Race No. 7
    G06500186Courtesy of SUZUKI OF AMERICA CORP.
  68. Remove snap ring (1) by using flat end rod or the like.
    Fig 59: Removing Snap Ring
    G06500187Courtesy 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 And Rear Planetary Ring Gear
    G06500188Courtesy of SUZUKI OF AMERICA CORP.
  70. Remove brake plate stopper spring (1) from transmission case.
    Fig 61: Identifying Brake Plate Stopper Spring
    G06500189Courtesy of SUZUKI OF AMERICA CORP.
  71. Remove 1st & reverse (No. 4) brake flange (1) from transmission case.
  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.
    74. Fig 62: Identifying 1st And Reverse Brake Flange And Brake Plates
    G06500190Courtesy of SUZUKI OF AMERICA CORP.
  74. Remove rear planetary gear assembly (1) from transmission case.
    Fig 63: Identifying Rear Planetary Gear Assembly
    G06500191Courtesy 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 And Thrust Needle Roller Bearing
    G06500192Courtesy of SUZUKI OF AMERICA CORP.
  76. Remove thrust needle roller bearing (1) from transmission case.
    Fig 65: Identifying Thrust Needle Roller Bearing
    G06500193Courtesy 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: Removing Snap Ring
    G06500194Courtesy of SUZUKI OF AMERICA CORP.
  78. Remove 1st & reverse (No. 4) brake return spring (1).
    Fig 67: Identifying 1st And Reverse (No. 4) Brake Return Spring
    G06500195Courtesy of SUZUKI OF AMERICA CORP.
  79. Remove 1st & reverse (No. 4) brake piston (1) by applying compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) into oil hole (2) of transmission case.
  80. Remove O-ring from 1st & reverse (No. 4) brake piston (1).
    Fig 68: Removing 1st And Reverse (No. 4) Brake Piston Using Compressed Air
    G06500196Courtesy of SUZUKI OF AMERICA CORP.
  81. Remove brake reaction sleeve (1) by using special tools.

    Special Tool 

    (A): 09920-20310 

    Fig 69: Removing Brake Reaction Sleeve Using Special Tools
    G06500197Courtesy of SUZUKI OF AMERICA CORP.
  82. Remove 1st & reverse brake inner piston (1) by using special tools.

    Special Tool 

    (A): 09920-20310 

    Fig 70: Removing 1st And Reverse Brake Inner Piston Using Special Tools
    G06500198Courtesy of SUZUKI OF AMERICA CORP.
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