Automatic Transmission Unit Assembly Inspection

Reference: AUTOMATIC TRANSMISSION ASSEMBLY COMPONENTS

Reference: AUTOMATIC TRANSMISSION UNIT DISASSEMBLY

Reference: AUTOMATIC TRANSMISSION UNIT ASSEMBLY

Hold reverse clutch hub (1), and turn one-way No. 2 clutch assembly (2).
Check that one-way No. 2 clutch assembly (2) can be turned freely (3) clockwise and locked (4) counterclockwise.

Fig 1: Checking One-Way No. 2 Clutch Assembly Operation
Courtesy of SUZUKI OF AMERICA CORP.
Check that sliding surfaces of discs, plate and flange are not worn or burnt. If necessary replace them.
NOTE:
- If disc lining is exfoliated, discolored or worn hardly, replace all discs.
- If only a part of printed numbers is corroded, replace all discs.
- Before assembling new discs, soak them in A/T fluid for at least 2 hours.
  
  Fig 2: Identifying Clutch Disc
  Courtesy of SUZUKI OF AMERICA CORP.
Measure free length of 2nd (No. 3) brake piston return spring including spring seat.
2nd (No. 3) brake piston return spring free length

"a": 15.72 mm (0.619 in.)
NOTE:
- Do not apply excessive force when measuring spring free length.
- Perform measurement at several points.
Fig 3: Measuring Free Length Of 2nd (No. 3) Brake Piston Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Measure planetary pinion gear thrust clearance by using thickness gauge.
If clearance exceeds limit, replace front planetary gear assembly.

Front planetary pinion gear thrust clearance

Standard: 0.20 - 0.60 mm (0.008 - 0.024 in.)

Limit: 0.65 mm (0.026 in.)

Fig 4: Measuring Planetary Pinion Gear Thrust Clearance
Courtesy of SUZUKI OF AMERICA CORP.
Measure inside diameter of front planetary gear assembly bushing.
If inside diameter exceeds limit, replace front planetary gear assembly.

Front planetary gear assembly bushing inside diameter limit

57.48 mm (2.263 in.)

Fig 5: Measuring Inside Diameter Of Front Planetary Gear Assembly Bushing
Courtesy of SUZUKI OF AMERICA CORP.
Install one-way No. 1 clutch assembly (1) to one-way No. 1 clutch inner race (2).
Hold one-way No. 1 clutch inner race (2), and turn one-way No. 1 clutch assembly (1).

Check that one-way No. 1 clutch assembly (1) can be turned freely (3) counterclockwise and locked (4) clockwise.

Remove one-way No. 1 clutch assembly (1) from one-way No. 1 clutch inner race (2).

Fig 6: Checking One-Way No. 1 Clutch Assembly Operation
Courtesy of SUZUKI OF AMERICA CORP.
Measure free length of No. 1 brake piston return spring including spring seat.
No. 1 brake piston return spring free length

"a": 17.05 mm (0.671 in.)
NOTE:
- Do not apply excessive force when measuring spring free length.
- Perform measurement at several points.
  
  Fig 7: Checking No. 1 Brake Piston Return Spring Free Length
  Courtesy of SUZUKI OF AMERICA CORP.
Measure free length of No. 2 brake piston return spring including spring seat.
No. 2 brake piston return spring free length

"a": 17.45 mm (0.687 in.)
NOTE:
- Do not apply excessive force when measuring spring free length.
- Perform measurement at several points.
Fig 8: Checking No. 2 Brake Piston Return Spring Free Length
Courtesy of SUZUKI OF AMERICA CORP.
Measure planetary pinion gear thrust clearance by using thickness gauge.
If clearance exceeds limit, replace middle planetary gear assembly.

Middle planetary pinion gear thrust clearance

Standard: 0.12 - 0.68 mm (0.005 - 0.027 in.)

Limit: 0.73 mm (0.029 in.)

Fig 9: Checking Middle Planetary Pinion Gear Thrust Clearance
Courtesy of SUZUKI OF AMERICA CORP.
Hold rear planetary ring gear flange sub assembly (1) and turn one-way No. 3 clutch assembly (2).
Check that one-way No. 3 clutch assembly (2) can be turned freely (3) counterclockwise and locked (4) clockwise.

Fig 10: Checking One-Way No. 3 Clutch Assembly Operation
Courtesy of SUZUKI OF AMERICA CORP.
Measure inside diameter of planetary ring gear assembly bushing.
If inside diameter exceeds limit, replace planetary ring gear.

Planetary ring gear bushing inside diameter limit

32.19 mm (1.267 in.)

Fig 11: Checking Planetary Ring Gear Bushing Inside Diameter
Courtesy of SUZUKI OF AMERICA CORP.
Set intermediate shaft between two "V" blocks, and measure its runout by using a dial gauge.
If runout exceeds limit, replace intermediate shaft with new one.

Intermediate shaft runout limit

0.08 mm (0.003 in.)

Fig 12: Checking Intermediate Shaft Runout
Courtesy of SUZUKI OF AMERICA CORP.

Measure outside diameter of intermediate shaft positions shown in figure.

If outside diameter is below limit, replace intermediate shaft with new one.

Outside diameter of intermediate shaft

INTERMEDIATE SHAFT SPECIFICATION

	Standard	Limit
A	25.962 - 25.975 mm (1.022 - 1.023 in.)	25.912 mm (1.020 in.)
B	25.962 - 25.975 mm (1.022 - 1.023 in.)	25.912 mm (1.020 in.)
C	32.062 - 32.075 mm (1.262 - 1.263 in.)	32.012 mm (1.260 in.)
D	32.062 - 32.075 mm (1.262 - 1.263 in.)	32.012 mm (1.260 in.)

Fig 13: Checking Outside Diameter Of Intermediate Shaft

Courtesy of SUZUKI OF AMERICA CORP.

Measure planetary pinion gear thrust clearance by using thickness gauge.
If clearance exceeds limit, replace rear planetary gear assembly.

Rear planetary pinion gear thrust clearance

Standard: 0.2 - 0.6 mm (0.008 - 0.024 in.)

Limit: 0.65 mm (0.026 in.)

Fig 14: Checking Rear Planetary Pinion Gear Thrust Clearance
Courtesy of SUZUKI OF AMERICA CORP.
Measure inside diameter of rear planetary gear assembly bushing.
If inside diameter exceeds limit, replace rear planetary gear assembly.

Rear planetary gear inside diameter limit

20.075 mm (0.790 in.)

Fig 15: Checking Rear Planetary Gear Inside Diameter
Courtesy of SUZUKI OF AMERICA CORP.
Measure free length of 1st & reverse (No. 4) brake return spring including spring seat.
1st & reverse (No. 4) brake return spring free length

"a": 23.74 mm (0.935 in.)
NOTE:
- Do not apply excessive force when measuring spring free length.
- Perform measurement at several points.
  
  Fig 16: Checking 1st And Reverse (No. 4) Brake Return Spring Free Length
  Courtesy of SUZUKI OF AMERICA CORP.