Automatic Transmission Unit Reassembly

Reference: AUTOMATIC TRANSMISSION UNIT DISASSEMBLY 

Reference: BEARING AND RACE INSTALLATION SPECIFICATION 

1. Measure inside diameter of transmission case bushing. If inside diameter exceeds limit, replace transmission case.

   Transmission case bushing inside diameter standard 

   38.113 - 38.138 mm (1.5005 - 1.5015 in.) 

   Fig 1: Measuring Transmission Case Bushing Inside Diameter Using Tool

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2. After applying A/T fluid to new O-rings, install them to reverse brake piston (3), reaction sleeve (2) and secondary reverse piston (1).
   Fig 2: Identifying Reverse Brake Piston, Secondary Reverse Piston And Reaction Sleeve

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3. Measure free length of reverse brake piston return spring.

   Standard free length of reverse brake piston return spring 

   16.84 mm (0.663 in.) 

4. Install reverse brake piston assembly and brake piston return spring to transmission case, using care not to damage O-ring. Then install snap ring (1) with special tools.
   NOTE:

   • Install so that opening in snap ring (1) will not align with any of 3 lugs of spring seat.
   • Do not compress spring more than necessary and do not allow it fall or tilt.

   Special Tool 

   (A): 09941-84510 

   (B): 09944-88210 

   Fig 3: Installing Snap Ring Using Special Tools

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5. Prepare a stand as shown. It is necessary because work will be done with transmission case (1) set upright from this step on.
   NOTE:

   • To protect transmission case against damage, nylon cloth on stand where case contacts.
   • To facilitate work, use a stand with the size as shown in figure.
   Fig 4: Holding Transmission Case On Stand

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6. Install thrust bearing (1) and thrust bearing race (2) after lubricating them with grease.
   NOTE: Make sure that thrust bearing output shaft race is installed in proper direction.
   Fig 5: Identifying Thrust Bearing And Thrust Bearing Race

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7. Install brake applying tube (1) so that its lug (2) fits in a transmission case (4). After installation, check that 4 dents (3) along the underside of brake applying tube fit inside of reverse brake piston.
   Fig 6: Identifying Brake Applying Tube, Lug, Transmission Case And Dents

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8. Install leaf spring (1) as shown in figure.
   Fig 7: Identifying Leaf Spring

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9. Remove reverse brake reaction plate of planetary gear assembly and align lugs of reverse brake plate, reverse brake disc and reverse brake backing plate. Install planetary gear assembly to transmission case so that aligned lugs fit in groove in transmission case.
   Fig 8: Identifying Planetary Gear Assembly

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10. Measure clearance between reverse brake plate and lugs of transmission case. If measured value is less than standard range, it is possible that something is installed improperly or dust or fluid is on reverse brake disc, etc. If it exceeds standard range, adjust it to standard clearance with selective reverse brake backing plates as shown after making sure reverse brake disc, reverse brake plate and reverse brake backing plate are in good condition. If the clearance is out of specification, select another plate with suitable thickness from the list below and replace it.

    Standard clearance between reverse brake plate and lugs of transmission case 

    0.52 - 1.27 mm (0.020 - 0.050 in.) 

    AVAILABLE PLATE THICKNESS
    
    

    Identification No.	Thickness
    No identification	2.95 - 3.05 mm (0.116 - 0.120 in.)
    "325"	3.20 - 3.30 mm (0.126 - 0.130 in.)
    "350"	3.45 - 3.55 mm (0.136 - 0.140 in.)
    "375"	3.70 - 3.80 mm (0.146 - 0.150 in.)
    "400"	3.95 - 4.05 mm (0.156 - 0.159 in.)
    "425"	4.20 - 4.30 mm (0.165 - 0.169 in.)

    Fig 9: Measuring Clearance Between Reverse Brake Plate And Lugs Of Transmission Case

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11. Install reverse brake reaction plate so that its lug with dent (1) comes to specified position as shown in figure.
    Fig 10: Identifying Reverse Brake Reaction Plate Lug Dent Position

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12. Using flat end rod or the like, install retaining reaction plate ring (1). After installation, check that ring is in groove securely.
    Fig 11: Identifying Retaining Reaction Plate Ring

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13. After confirming that lugs of all brake plates and brake discs are in grooves securely, hold retaining ring (1) of planetary sun gear, install center support assembly by aligning bolt holes (2) in center support and transmission case.
    NOTE: Unless retaining ring of planetary sun gear is held, brake valve will fall down and it will make impossible to align fluid holes with bolt holes.
    Fig 12: Identifying Planetary Sun Gear Retaining Ring And Alignment Bolt Holes

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14. Tighten center support bolts by certain amount at a time till specified tightening torque is obtained.

    Tightening torque 

    Center support bolt: 26 N.m (2.6 kgf-m, 19.0 lbf-ft) 

    Fig 13: Tightening Center Support Bolt Using Tool

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15. Install direct clutch assembly by aligning splines in direct clutch cylinder with planetary sun gear.
    NOTE: Ends of splines in direct clutch cylinder and planetary sun gear should be almost aligned.
    Fig 14: Identifying Direct Clutch Assembly

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16. Apply grease to thrust bearing (2) and bearing races (1), and then install them to direct clutch.
    Fig 15: Identifying Thrust Bearing And Bearing Races

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17. Install forward clutch assembly by putting all lugs of direct clutch disc hub together and matching them with groove cut in direct clutch input hub, and at the same time aligning splines in forward clutch hub with inner shaft.
    Fig 16: Installing Forward Clutch Assembly

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18. When clutch disc and plate have been replaced, check height difference between forward clutch input shaft and transmission case (1) by measuring as shown in figure.
    NOTE: If measured value is less than standard value, remove forward clutch assembly and install it again.

    Standard height difference between forward clutch input shaft and transmission case 

    "a": About 2.0 mm (0.079 in.) 

    Fig 17: Identifying Height Difference Between Forward Clutch Input Shaft And Transmission Case

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19. Apply grease to thrust bearing (1) and bearing race (2), and then install them to forward clutch input shaft.
    Fig 18: Identifying Thrust Bearing And Bearing Race

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20. Install O/D case by aligning cutout in O/D case (1) and that in transmission case.
    Fig 19: Aligning Cutout In O/D Case And Transmission Case

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21. Apply grease to thrust washers (1) and install them to O/D planetary gear (2) and planetary ring gear (3), and then install O/D input shaft assembly to O/D case.
    NOTE: Fit claws of thrust washer into holes securely.
    Fig 20: Installing Thrust Washer To O/D Planetary Gear

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22. When clutch disc or plate has been replaced, check height difference between O/D case (1) and O/D clutch cylinder (2) by measuring it as shown in figure.
    NOTE: Measure height difference at the highest point along inner circumference of O/D clutch cylinder.

    Standard height difference between O/D case and O/D clutch cylinder 

    "a": About 3.5 mm (0.138 in.) 

    Fig 21: Identifying Height Difference Between O/D Case And O/D Clutch Cylinder

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23. Apply A/T fluid to new housing O-ring and install it to O/D case. Then install converter housing (1) and tighten housing bolt to specified torque.

    Tightening torque 

    Torque converter housing bolt (a): 35 N.m (3.5 kgf-m, 25.5 lbf-ft) 

    Torque converter housing bolt (b): 58 N.m (5.8 kgf-m, 42.0 lbf-ft) 

    Fig 22: Converter Housing And Mounting Bolt With Torque Specifications

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24. Apply grease to bearing race (1) and thrust bearing (2) and install them to O/D clutch cylinder.
    Fig 23: Identifying Bearing Race And Thrust Bearing Grease Applying Area

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25. Apply A/T fluid to new oil pump cover O-ring and install it to oil pump assembly. Then install oil pump assembly aligning bolt holes in O/D case with those in transmission case oil pump assembly. Apply seal packing to oil pump assembly 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): 22 N.m (2.2 kgf-m, 16.0 lbf-ft) 

    Fig 24: Identifying Oil Pump Bolt

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26. Apply 200 - 400 kPa (2 - 4 kgf/cm² , 29 - 58 psi) air pressure into fluid holes in figure as numbered and check operation sound of each part.
    Fig 25: Identifying Air Pressure Into Fluid Holes Applying Area

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27. Take down transmission from stand and install new gasket and cover plate (1).
    Fig 26: Identifying Transmission Cover Plate

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28. Measure clearance in shaft direction by applying dial gauge (1) to output shaft as shown in figure.

    Standard clearance in shaft direction 

    0.3 - 0.9 mm (0.012 - 0.035 in.) 

    Fig 27: Measuring Clearance In Shaft Direction By Applying Dial Gauge

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29. Check that inner shaft runs smoothly.
30. Apply grease to lip of new oil seal and drive in oil seal with special tool till it contacts transmission case.

    Special Tool 

    (A): 09923-46020 

    Fig 28: Driving Oil Seal Using Special Tool

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31. Install a new spacer (1) to manual shift lever (2).
32. Install manual shift shaft (3) to transmission case through manual shift lever.
    Fig 29: Installing Manual Shift Shaft To Transmission Case Through Manual Shift Lever

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33. Drive in manual shift lever pin (1) by using hammer.
    Fig 30: Driving In Manual Shift Lever Pin Using Hammer

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34. 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 31: Aligning Hole In Sleeve Cover With Dent In Manual Shift Lever And Caulk

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35. Install parking lock pawl (2), parking pawl pin (1) and parking pawl spring (3).
    Fig 32: Identifying Parking Pawl Pin, Lock Pawl And Spring

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36. Connect parking lock rod (2) to manual shift lever (1) as shown in figure.
    Fig 33: Identifying Manual Shift Lever And Parking Lock Rod

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37. 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 kgf-m, 5.5 lbf-ft) 

    Fig 34: Parking Lock Pawl Bracket And Bolts With Torque Specifications

    Courtesy of SUZUKI OF AMERICA CORP.
38. Apply A/T fluid to new O-ring and spring and install them to accumulator piston and install accumulator piston to transmission case.
    ACCUMULATOR SPRING SPECIFICATION
    
    

    Accumulator piston	Accumulator spring
    	Spring free length "a" (mm (in))	Color
    Forward clutch	70.70 (2.783)	No paint
    Direct clutch	57.36 (2.258)	No paint
    Second brake	56.16 (2.211)	Purple

    Fig 35: Identifying Accumulator Spring Free Length

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39. After confirming that accumulator piston is pushed all the way down, match pin of manual shift lever with groove in manual valve.
    Fig 36: Identifying Accumulator Piston Assembly

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40. Fix valve body (1) by using bolts with each nominal length as indicated in figure and tighten to specified torque.

    Tightening torque 

    Valve body bolt: 10 N.m (1.0 kgf-m, 7.5 lbf-ft) 

    Valve body bolt nominal length 

    "a": 28 mm (1.10 in.) 

    "b": 30 mm (1.18 in.) 

    "c": 36 mm (1.42 in.) 

    "d": 45 mm (1.77 in.) 

    Fig 37: Identifying Valve Body Bolt Nominal Length

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41. Install O/D brake applying tube (1).
    Fig 38: Identifying O/D Brake Applying Tube

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42. Lubricate new O-ring with A/T fluid and attach it to grommet of solenoid wire harness. Then connect solenoid wire harness to transmission case and fix it with solenoid wire harness clamp. Connect each connector to solenoid. And install new gasket and brake applying cover.

    Tightening torque 

    Solenoid connector bolt (a): 16 N.m (1.6 kgf-m, 11.5 lbf-ft) 

    Fig 39: Solenoid Connector Bolt With Torque Specifications

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43. Connect solenoid connector to each solenoid.
44. Install oil strainer (1) to valve body assembly.

    Tightening torque 

    Oil strainer bolt (a): 5.5 N.m (0.55 kgf-m, 4.0 lbf-ft) 

    Fig 40: Oil Strainer And Mounting Bolt With Torque Specifications

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45. Install transmission oil pan (1) with new oil pan gasket.
    NOTE: Align cutout in oil pan gasket with one in transmission case.

    Tightening torque 

    Transmission oil pan bolt: 4.5 N.m (0.45 kgf-m, 3.5 lbf-ft) 

    Fig 41: Identifying Transmission Oil Pan

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46. With wood rough key attached to output shaft, install sensor rotor (2) by aligning its key groove with wood rough key and install C-ring (1).
    Fig 42: Identifying Sensor Rotor And C-Ring

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47. Install adapter case (1) with new adapter gasket to transmission case and tighten adapter case bolts to specified torque.

    Tightening torque 

    Adapter case bolt (a): 23 N.m (2.3 kgf-m, 17.0 lbf-ft) 

    Fig 43: Adapter Case And Mounting Bolts With Torque Specifications

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48. Apply A/T fluid to new O-rings and install them to input shaft speed sensor (1) and output shaft speed sensor (2), and then install input shaft speed sensor (1) and output shaft speed sensor (2).
    Fig 44: Identifying Input And Output Shaft Speed Sensor

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49. After turning manual shift shaft fully rearward, turn it back by 2 notches and set it to "N" range. Then install transmission range sensor, lock washer and nut and tighten nut. After tightening it, bend claws of lock washer.

    Tightening torque 

    Manual shift shaft nut (a): 12.5 N.m (1.25 kgf-m, 9.0 lbf-ft) 

50. With neutral reference line (1) and cut groove (2) in switch aligned, tighten lock bolt.

    Tightening torque 

    Transmission range sensor bolt (b): 5.3 N.m (0.53 kgf-m, 4.0 lbf-ft) 

    Fig 45: Converter Housing, Neutral Reference Line And Mounting Bolts With Torque Specifications

    Courtesy of SUZUKI OF AMERICA CORP.
51. Confirm that torque converter is fully fitted in transmission. Confirmation can be done by measuring dimension between end surface of housing case (2) and drive plate installation seat.

    Standard dimension between end surface of case housing and drive plate installation seat "a" 

    17.4 mm (0.69 in.) 

52. Check that torque converter turns smoothly and apply grease to center piece (1) of torque converter.
    Fig 46: Identifying Clearance Between End Surface Of Case Housing And Drive Plate

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