Suzuki Grand Vitara JB627. Manual — part 235

5A-124 Automatic Transmission/Transaxle:

15) Compress clutch balancer No.1 and forward clutch

return spring (1) until the clutch balancer No.1 is
lowered to the place 1 – 2 mm (0.039 – 0.078 in.)
from the snap ring groove by using special tool and
hydraulic press, and then remove snap ring (2).

CAUTION

!

Be careful when applying pressure, for
overpressure will cause forward clutch return
spring to deform.

NOTE
Set special tool to the width of “a” 68 mm
(2.652 in.) as shown in figure.

Special tool
(A): 09926–96520

16) Remove clutch balancer No.1 (1) and forward clutch

return spring (2) from input shaft assembly.

17) Remove forward clutch piston (1) from input shaft

assembly (2) by applying compressed air (392 kPa,
4.0 kg/cm

2

, 57 psi) into oil hole (3) of input shaft

assembly as shown in figure.

18) Remove reverse clutch flange (1) from clutch drum

assembly (2).

19) Remove 2 snap rings (1) from clutch drum assembly

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

20) Remove direct clutch flange “F”, direct clutch plates

“P” and direct clutch discs “D” from clutch drum
assembly.

2

(A)

“a”

1

I4JA01512160-01

1

2

I4JA01512161-01

3

2

1

I4JA01512162-01

1

2

I4JA01512163-01

1

2

I4JA01512164-01

F

P

D

I6JB01510040-01

Automatic Transmission/Transaxle: 5A-125

21) Compress clutch balancer No.3 and reverse clutch

return spring (1) until the clutch balancer No.3 is
lowered to the place 1 – 2 mm (0.039 – 0.078 in.)
from the snap ring groove by using special tool and
hydraulic press, and then remove snap ring (2).

CAUTION

!

Be careful when applying pressure, for
overpressure will cause reverse clutch return
spring to deform.

Special tool
(A): 09926–96040

22) Remove reverse clutch return spring (1) and O-ring

(2) from reverse clutch piston.

23) Remove reverse clutch piston sub assembly from

clutch drum sub assembly (1).

24) Compress clutch balancer No.2 and direct clutch

return spring (1) until the clutch balancer No.2 is
lowered to the place 1 – 2 mm (0.039 – 0.078 in.)
from the snap ring groove by using special tool and
hydraulic press, and then remove snap ring (2).

CAUTION

!

Be careful when applying pressure, for
overpressure will cause direct clutch return
spring to deform.

Special tool
(A): 09926–96040

25) Using 2 screw drivers, remove direct clutch piston

sub assembly (1) from clutch drum.

26) Remove clutch balancer No.2 (1) and direct clutch

return spring (2) from direct clutch piston sub
assembly.

2

1

(A)

I4JA01512166-01

1

2

I4JA01512167-01

1

I4JA01512168-01

1

(A)

2

I4JA01512169-01

1

I4JA01512170-01

1

2

I4JA01512171-01

5A-126 Automatic Transmission/Transaxle:

Clutch Drum & Input Shaft Assembly
Reassembly

S6JB0B5106037

1) Apply A/T fluid to new 2 O-rings (1) and then install

O-rings to direct clutch piston.

2) Install clutch balancer No.2 (1) and direct clutch

return spring (2) to direct clutch piston sub assembly.

3) Apply A/T fluid to new O-ring (1), and then install O-

ring to clutch drum sub assembly.

4) Press-fit direct clutch piston into clutch drum by

hands.

5) Compress clutch balancer No.2 (1) until the clutch

balancer No.2 is lowered to the place 1 – 2 mm
(0.039 – 0.078 in.) from the snap ring groove by
using special tool and hydraulic press.

Special tool
(A): 09926–96040

CAUTION

!

Be careful when applying pressure, for
overpressure will cause direct clutch return
spring to deform.

6) Install snap ring (1) as set snap ring end gap

between snap ring stoppers (2) of clutch balancer
No.2.

7) Apply A/T fluid to new O-ring (1), and then install O-

ring to reverse clutch piston sub assembly.

1

I4JA01512172-01

1

2

I4JA01512173-01

1

I4JA01512174-01

1

(A)

I4JA01512175-01

2

2

1

I4JA01512176-01

1

I4JA01512177-01

Automatic Transmission/Transaxle: 5A-127

8) Press-fit clutch drum sub assembly (1) into reverse

clutch piston (2) by hands.

CAUTION

!

Do not twist or deviate O-rings during
installation.

9) Apply A/T fluid to new O-ring (1), and then install O-

ring to reverse clutch piston sub assembly.

10) Install reverse clutch return spring (2) onto reverse

clutch piston sub assembly.

11) Place clutch balancer No.3 (1) onto reverse clutch

piston sub assembly.

CAUTION

!

Do not twist or deviate O-ring during
installation.

12) Compress clutch balancer No.3 (1) until the clutch

balancer No.3 is lowered to the place 1 – 2 mm
(0.039 – 0.078 in.) from the snap ring groove by
using special tool and hydraulic press, and then
install snap ring.

CAUTION

!

Be careful when applying pressure, for
overpressure will cause reverse clutch return
spring to deform.

Special tool
(A): 09926–96040

13) Set end gap of snap ring (1) in piston as shown in

figure.

1

2

I4JA01512178-01

2

1

I4JA01512179-01

1

(A)

I4JA01512180-01

1

I4JA01512181-01