How to Assembly Automatic Transmission Unit for Suzuki Grand Vitara

When replacing Sukuki pressure control solenoid valve and/or TCC pressure control solenoid
valve, it is strictly required to replace it together with valve body assembly as a set.
Replacing pressure control solenoid valve and/or TCC pressure control solenoid valve
independently may cause excessive shift shock.

Suzuki EPC 2019 Download

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.)
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)

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): 09926–98320
(B): 09926–98390
(C): 09944–88210 

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, spread cloth on stand where case contacts.
• A stand of such size as shown in the figure will facilitate work.

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.
7) Install brake applying tube (1) so that its lug (2) fits in a in transmission case (4). After installation, check that 4 lugs (3) along the underside of brake applying tube fit inside of reverse brake piston.
8) Install leaf spring (1) as shown in figure.
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.
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.)

2019 2014 Suzuki Worldwide Automotive EPC Free Download
Available plate thickness
I5JB0A510160-01
2
1 3
4
I5JB0A510130-02
1
I5JB0A510131-02
Identification No. Thickness
No identification 2.95 – 3.05 mm
(0.116 – 0.120 in.)
“325” 3.20 – 3.30 mm
(0.126 – 0.120 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.)
IYSQ01510241-015A-37 Automatic Transmission/Transaxle:
11) Install reverse brake reaction plate so that its lug with dent (1) comes to specified position as shown in figure.
12) Using screwdriver with vinyl tape or the like wound at its tip, install retaining reaction plate ring (1). After installation, check that ring is in groove securely. 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 gets off center support and that will make it impossible to align fluid holes with bolt holes.
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 lbft)
IYSQ01510242-01
1
I5JB0A510132-01
1
I5JB0A510084-01
1
2
I5JB0A510133-01
IYSQ01510246-01Automatic Transmission/Transaxle: 5A-38
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 come almost in
match.
16) Apply grease to thrust bearing (1) and bearing races
(2), and then install them to direct clutch.
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.
NOTE
Use care not to let forward clutch rear No.1 race and thrust bearing installed to forward clutch hub fall off.
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 the 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.)
19) Apply grease to thrust bearing (1) and bearing race
(2), and then install them to forward clutch input shaft.
20) Install O/D case by aligning cutout in O/D case (1) and that in transmission case.
NOTE
Use care not to drop thrust rear race installed to O/D case.
IYSQ01510247-01
2
1
I5JB0A510134-01
IYSQ01510249-01
2. Forward clutch
2. Cutout in automatic transmission
2
“a” 1
I5JB0A510135-01
2 1
I5JB0A510136-01
1
2
I5JB0A510137-025A-39 Automatic Transmission/Transaxle:
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.
• Use care not to drop thrust washer installed to O/D planetary gear.
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 the figure.
NOTE
Measure 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.)
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 lb-ft)
Torque converter housing bolt (b): 58 N·m (5.8 kgf-m, 42.0 lb-ft)
24) Apply grease to bearing race (1) and thrust bearing (2) and install them to O/D clutch cylinder.
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 lb-ft)
I5JB0A510138-01
I5JB0A510161-01
I5JB0A510162-01
1 2
I5JB0A510139-01
IYSQ01510257-01Automatic Transmission/Transaxle: 5A-40
26) Apply 2 – 4 kg/cm2 air pressure into fluid holes in the figure as numbered and check operation sound of each part.
27) Take clown transmission from stand and install new gasket and cover plate (1).
28) Measure clearance in shaft direction by applying dial gauge (1) to output shaft as shown in the figure.
Standard clearance in shaft direction
0.3 – 0.9 mm (0.012 – 0.035 in.)
29) Check that inner shaft runs smoothly.
30) Apply grease to lip of new oil lip seal and drive in oil lip seal with special tool till it contacts transmission case.

Special tool
(A): 09923–46020
31) Install a new spacer (1) to manual shift lever (2).
32) Install manual shift shaft (3) to transmission case through manual shift lever.
33) Drive in manual shift lever pin (1) by using hammer.
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.
1. O/D clutch 5. Second coast brake
2. O/D brake 6. Second brake
3. Forward clutch 7. Reverse brake
4. Direct clutch
IYSQ01510258-01
1
I5JB0A510089-01
IYSQ01510259-01
IYSQ01510261-01
2
1
3
I4JA01512266-01
1
I4JA01512267-01
1
I4JA01512268-015A-41 Automatic Transmission/Transaxle:
35) Install parking lock pawl (2), parking pawl pin (1) and
parking pawl spring (3).
36) Connect parking lock rod (2) to manual shift lever (1)
as shown in the figure.
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 kgfm, 5.5 lb-ft)
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
39) After confirming that accumulator piston is pushed all
the way down, match pin of manual shift lever with
groove in manual valve.
2
1 3
I4JA01512269-01
1
2
I4JA01512270-01
1
2, (a)
I4JA01512271-01
Accumulator
piston
Accumulator spring
Spring free
length “a” Color
Forward clutch 75.03 White + Blue
Direct clutch 57.74 White + Purple
Second brake 56.16 Purple
1. Forward clutch accumulator piston
2. Direct clutch accumulator piston
3. Second brake accumulator piston
4. Accumulator spring
3 4
1
2
“a”
I5JB0A510140-02
IYSQ01510269-01Automatic Transmission/Transaxle: 5A-42
40) Fix valve body (1) by using bolts with each nominal
length as indicated in the figure and tightening to
specified torque.
Tightening torque
Valve body bolt: 10 N·m (1.0 kgf-m, 7.5 lb-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.)
41) Install O/D brake applying tube (1).
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
Transmission wire connector bolt (a): 16 N·m ( 1.6 kgf-m, 11.5 lb-ft)
43) Connect solenoid coupler 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 lbft)
45) Install transmission oil pan (1) with new oil pan gasket.
NOTE
Align cutout in oil pan gasket with that in transmission case.

Tightening torque
Transmission oil pan bolt: 4.5 N·m (0.45 kgf-m,
3.5 lb-ft)
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.

I5JB0A510072-015A-43 Automatic Transmission/Transaxle:
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): 31 N·m (3.1 kgf-m, 30.0 lbft)
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).
49) After turning manual shift shaft fully rearward, turn it back by 2 notches and set it to “N” range. Then

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Created on Jan 18th 2021 19:32. Viewed 231 times.

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