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.

Extract torque converter (1). And remove oil filler tube and dipstick.
CAUTION: Remove torque converter as much straight as possible. Leaning it may cause damage to oil seal lip.

Fig 1: Identifying Torque Converter And Torque Converter Housing
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft speed sensor (1) and output shaft speed sensor (2).
Remove 6 adapter case fixing bolts and then remove adapter case (3) and gasket.
NOTE: Use care not to cause damage to oil seal.

Fig 2: Identifying Input And Output Shaft Speed Sensor
Courtesy of SUZUKI OF AMERICA CORP.
Remove transmission range sensor (1).

Fig 3: Identifying Transmission Range Sensor
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-ring (1) and then remove speed sensor rotor (2).
NOTE: Use care not to loose rotor stop key.

Fig 4: Identifying C-Ring And Speed Sensor Rotor
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pump (1) by using special tools.
Special Tool

(A): 09913-65135

(B): 09927-66520

NOTE: Use care not to cause damage to shaft bushing surface.
Remove bearing at the rear of oil pump (1).
Remove O-ring from oil pump (1).
Holding input shaft (2) by hand, remove converter housing (3).

Fig 5: Identifying Input Shaft And Converter Housing
Courtesy of SUZUKI OF AMERICA CORP.
Check dimensions of overdrive (O/D) case (1) surface and clutch cylinder (2) surface for reassembly.
Remove overdrive (O/D) clutch assembly by holding input shaft (3).
Remove O/D case, bearing and bearing race.
NOTE: Confirm direction of bearing and bearing race for reassembly.

Fig 6: Identifying Dimensions Of Overdrive (O/D) Case Surface And Clutch Cylinder Surface
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pan (1) and oil pan gasket.
Then remove magnets from oil pan and clean them to steel particles etc.
NOTE:
- Hold oil pan with oil pan side down to prevent foreign material in oil pan from entering valve body.
- If iron powder is found, it is possible that bearing, gear or clutch plate is worn.
  
  Fig 7: Removing Oil Pan
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil strainer (1).

Fig 8: Identifying Oil Strainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove overdrive (O/D) brake apply tube (1).
Disconnect connectors, and then remove solenoid wire harness (2).

Fig 9: Identifying Overdrive (O/D) Brake Apply Tube And Solenoid Wire Harness
Courtesy of SUZUKI OF AMERICA CORP.
Remove valve body (1) mounting bolts as shown in figure.

Fig 10: Identifying Valve Body
Courtesy of SUZUKI OF AMERICA CORP.
Remove accumulator pistons (1) by blowing air into holes (2) as shown in figure.
NOTE: Hold accumulator piston (1) with nylon cloth while blowing.

Fig 11: Identifying Accumulator Pistons
Courtesy of SUZUKI OF AMERICA CORP.
Place transmission (1) upright as shown in figure.
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 12: Identifying Stand Dimension
  Courtesy of SUZUKI OF AMERICA CORP.
Check top surface level of forward clutch (2) against case (1) for reassembly.
Remove forward clutch.
NOTE: Confirm direction of bearing and bearing race for reassembly.

Fig 13: Identifying Top Surface Level Of Forward Clutch Against Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch (1).

Fig 14: Identifying Direct Clutch
Courtesy of SUZUKI OF AMERICA CORP.
Remove pawl bracket (1), and then parking lock rod (2) from manual shift lever.
Remove pawl spring (3), pawl pin and parking lock pawl (4).

Fig 15: Identifying Pawl Bracket, Parking Lock Rod And Pawl Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2 bolts (1) from valve body side.

Fig 16: Identifying Valve Body Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove center support assembly (1).

Fig 17: Identifying Center Support Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining ring (1), planetary gear assembly leaf spring, bearing and bearing race.
NOTE:
- Use care not to cause damage to case when removing retaining ring.
- Confirm direction of bearing and bearing race for reassembly.
  
  Fig 18: Identifying Retaining Ring
  Courtesy of SUZUKI OF AMERICA CORP.
Remove apply tube.
Remove reverse brake return spring (1) using special tools.
Special Tool

(A): 09941-84510

(B): 09926-98320

Fig 19: Removing Reverse Brake Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse brake piston (1) by applying compressed air (400 - 800 kPa, 4 - 8 kgf/cm² , 57 - 113 psi) to oil hole (2).

Fig 20: Removing Reverse Brake Piston Using Compressed Air
Courtesy of SUZUKI OF AMERICA CORP.
Apply compressed air (400 - 800 kPa, 4 - 8 kgf/cm² , 57 - 113 psi) to oil hole (3) to remove brake reaction sleeve (1) and secondary reverse piston (2).
Remove brake reaction sleeve (1) and secondary reverse piston (2) by using special tools.
Special Tool

(A): 09920-20310

Fig 21: Removing Brake Reaction Sleeve And Secondary Reverse Piston
Courtesy of SUZUKI OF AMERICA CORP.
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 22: Removing Sleeve Cover
  Courtesy 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 23: Removing Manual Shift Lever And Sleeve Cover
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal (1) from both sides of transmission case.

Fig 24: Removing Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Remove cover plate (1).

Fig 25: Identifying Cover Plate
Courtesy of SUZUKI OF AMERICA CORP.