Suzuki Grand Vitara JB416 / JB420. Service manual — part 241

5A-98 Automatic Transmission/Transaxle:

Automatic Transmission Unit Disassembly

S5JB0A5106067

1) Extract torque converter. 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.

2) Remove input shaft speed sensor (1) and output

shaft speed sensor (2).

3) Remove 6 adapter case fixing bolts and then remove

adaptor case (3) and gasket.

NOTE
Use care not to cause damage to oil seal.

4) Remove shift switch (1).

5) Remove C-ring (1) and then remove speed sensor

rotor (2).

NOTE
Use care not to loose rotor stop key.

6) 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.

7) Remove bearing at the rear of oil pump (1).
8) Remove O-ring from oil pump (1).
9) Holding input shaft (2) by hand, remove converter

housing (3).

1. Torque converter
2. Converter housing

1

2

I5JB0A510069-01

1

2

3

I5JB0A510070-02

1

I5JB0A510071-01

1

2

I5JB0A510072-01

3

(B)

(A)

2

1

I5JB0A510073-01

Automatic Transmission/Transaxle: 5A-99

10) Check dimensions of overdrive (O/D) case (1)

surface and clutch cylinder (2) surface for
reassembly.

11) Remove overdrive (O/D) clutch assembly by holding

input shaft (3).

12) Remove O/D case, bearing and bearing race.

NOTE
Confirm direction of bearing and bearing
race for reassembly.

13) Remove oil pan (1).

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.

14) Remove oil strainer (1).

15) Remove overdrive (O/D) brake apply tube (1).
16) Disconnect couplers, and then remove transmission

wire connector (2).

17) Remove valve body (1) mounting bolts as shown in

the figure.

1

2

3

2

1

I5JB0A510074-01

IYSQ01510094-01

1

I5JB0A510075-01

1

2

I5JB0A510077-02

1

I5JB0A510076-01

5A-100 Automatic Transmission/Transaxle:

18) Remove accumulator pistons (1) by blowing air into

holes (2) as shown in the figure.

NOTE
Hold accumulator piston (1) with shop cloth
while blowing.

19) Place transmission (1) upright as shown in the

figure.

NOTE

• To prevent transmission case from getting

damaged, protect its contacting surface
with stand by using shop cloth or the like.

• A stand of such size as shown in the figure

will facilitate work.

20) Check top surface level of forward clutch (2) against

case (1) for reassembly.

21) Remove forward clutch.

NOTE
Confirm direction of bearing and bearing
race for reassembly.

22) Remove direct clutch (1).

23) Remove pawl bracket (1), and then parking lock rod

(2) from manual shift lever.

24) Remove pawl spring (3), pawl pin and parking rock

pawl (4).

25) Remove 2 bolts (1) from valve body side.

A: 50 mm (1.9 in.)
B: 350 mm (13.8 in.)

C: 400 mm (15.7 in.)
D: 200 mm (7.9 in.)

1

2

I5JB0A510078-04

1

C

A

D

B

I5JB0A510079-01

2

2

1

1

I5JB0A510080-01

1

I5JB0A510081-01

4

3

2

1

I5JB0A510082-01

1

I5JB0A510083-01

Automatic Transmission/Transaxle: 5A-101

26) Remove center support assembly (1).

27) 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.

28) Remove apply tube.
29) Remove reverse brake return spring (1) using

special tools.

Special tool
(A): 09926–98390
(B): 09944–88210
(C): 09926–98320

30) Remove reverse brake piston (1) by applying

compressed air (400 – 800 kPa, 4 – 8 kg/cm

2

, 57 –

113 psi) to oil hole (2).

31) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm

2

,

57 – 113 psi) to oil hole (3) to remove brake reaction
sleeve (1) and secondary reverse piston (2).

32) Remove brake reaction sleeve (1) and secondary

reverse piston (2) by using special tools.

Special tool
(A): 09920–20310

2. Nut M12 x 1.75

IYSQ01510104-01

1

I5JB0A510084-01

(A)

(C)

(B)

2

1

I5JB0A510085-01

1

2

I5JB0A510086-02

3

(A)

(A)

(A)

1

2

I5JB0A510087-02