Suzuki Grand Vitara JB627. Manual — part 234

5A-120 Automatic Transmission/Transaxle:

Oil Pump Inspection

S6JB0B5106034

• Measure inside diameter of oil pump body bushing.

If inside diameter exceeds limit, replace oil pump
body.

Oil pump body bushing inside diameter limit
38.188 mm (1.504 in.)

• Measure inside diameter of stator shaft assembly

bushing.
If inside diameter exceeds limit, replace stator shaft
assembly.

Stator shaft assembly bushing inside diameter
limit
Torque converter side: 21.577 mm (0.850 in.)
Output shaft side: 32.08 mm (1.263 in.)

• Check oil pump body clearance of driven gear.

Push driven gear (1) to one side of oil pump body (2).
Using a feeler gauge, measure clearance between
driven gear (1) and oil pump body (2).
If clearance exceeds standard value, replace oil pump
assembly.

Clearance between driven gear and oil pump body
Standard: 0.10 – 0.17 mm (0.004 – 0.007 in.)

• Check tip clearance of driven gear.

Measure radial clearance between driven and drive
gears tooth tip.
If clearance exceeds standard value, replace oil pump
assembly.

Tip clearance between driven gear and drive gear
Standard: 0.07 – 0.15 mm (0.003 – 0.006 in.)

• Check side clearance of both gears.

Using a straightedge (1) and a feeler gauge, measure
side clearance between gears and oil pump body.
If clearance exceeds standard value, replace oil pump
assembly.

Side clearance between gears and oil pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.002 in.)

I4JA01512140-01

I4JA01512141-01

1

2

I4JA01512142-01

I4JA01512143-01

1

I4JA01512144-01

Automatic Transmission/Transaxle: 5A-121

Clutch Drum & Input Shaft Assembly Components

S6JB0B5106035

1

23

38

39

25

26

27

29

30

31

32

33

34

35

36

37

28

18

17

2

3

5

8

10

20

22

11

12

13

4

FLD

7

FLD

19

FLD

24

FLD

21

FLD

6

FLD

9

FLD

FLD

FLD

15

FLD

14

FLD

42

41

FLD

43

44

45

40

FLD

I6JB01510038-02

1. Snap ring

13. Snap ring

25. Clutch balancer No.1

37. Direct clutch hub

2. Clutch balancer No.3

14. Direct clutch plate

26. Snap ring

38. Thrust needle roller bearing

3. Reverse clutch return spring

15. Direct clutch disc

27. Forward clutch flange

39. Reverse clutch hub

4. O-ring

16. Direct clutch flange

28. Forward clutch disc

40. Reverse clutch disc

5. Reverse clutch piston

17. Snap ring

29. Forward clutch plate

41. Reverse clutch plate

6. O-ring

18. Reverse clutch flange

30. Forward clutch flange

42. Reverse clutch flange

7. O-ring

19. Input shaft oil seal ring

31. Snap ring

43. Clutch cushion plate

8. Clutch drum

20. Input shaft

32. Thrust needle roller bearing

44. Reverse clutch reaction sleeve

9. O-ring

21. O-ring

33. Thrust bearing race

45. Snap ring

10. Direct clutch piston

22. Forward clutch piston

34. Forward clutch hub

: Do not reuse.

11. Direct clutch return spring

23. Forward clutch return spring

35. Thrust bearing race No.2

: Apply A/T fluid

12. Clutch balancer No.2

24. O-ring

36. Thrust needle roller bearing

5A-122 Automatic Transmission/Transaxle:

Clutch Drum & Input Shaft Assembly
Disassembly

S6JB0B5106036

1) Place oil pump (1) onto torque converter (2), and

then place clutch drum and input shaft assembly (3)
onto oil pump (1).

2) Remove snap ring (1) from clutch drum and input

shaft assembly (2) by using flat end rod or the like.

3) Remove reverse clutch hub (1) with reverse clutch

reaction sleeve, clutch cushion plate, reverse clutch
flange, 4 reverse clutch discs and 3 reverse clutch
plates from clutch drum assembly.

4) Remove reverse clutch reaction sleeve (1) from

reverse clutch hub.

5) Remove clutch cushion plate (1), reverse clutch

flange “F”, reverse clutch plates “P” and reverse
clutch discs “D” from reverse clutch hub.

6) Remove direct clutch hub (1) from clutch drum

assembly.

7) Remove 2 thrust needle roller bearings (1) from

direct clutch hub.

3

1

2

I4JA01512146-01

1

2

I4JA01512147-01

1

I4JA01512148-01

1

I4JA01512149-01

1

P

D

F

I6JB01510039-01

1

I4JA01512151-01

1

I4JA01512152-01

Automatic Transmission/Transaxle: 5A-123

8) Remove forward clutch hub (1) from clutch drum

assembly.

9) Remove thrust bearing race No.2 (1) and thrust

bearing race (2) from forward clutch hub.

10) Remove thrust needle roller bearing (1) from clutch

drum assembly.

11) Remove input shaft assembly (1) from clutch drum

assembly.

12) Remove 3 oil seal rings (1) from input shaft

assembly.

13) Remove snap ring (1) from input shaft assembly (2)

by using flat end rod or the like.

14) Remove forward clutch flanges “F”, forward clutch

discs “D” and forward clutch plates “P” from input
shaft assembly.

1

I4JA01512153-01

1

2

I4JA01512154-01

1

I4JA01512155-01

1

I4JA01512156-01

1

I4JA01512157-01

1

2

I4JA01512158-01

F

D

P

F

I4JA01512159-01