Suzuki Grand Vitara JB627. Manual — part 242

5A-152 Automatic Transmission/Transaxle:

102)Clean threads of automatic transmission housing

bolts and bolt holes of transmission case, install
automatic transmission housing (1) to transmission
case.
Tighten 10 automatic transmission housing bolts to
specified torque.

NOTE
Make sure to use new converter housing
bolts (2) and (3).

Tightening torque
Automatic transmission housing bolt (a): 57
N·m (5.7 kgf-m, 41.5 lb-ft)
Automatic transmission housing bolt (b): 34
N·m (3.4 kgf-m, 24.5 lb-ft)

103)After applying A/T fluid to new O-ring and then

install automatic transmission breather pipe (1).

104)Install automatic transmission breather hose.

Tightening 2 automatic transmission breather pipe
bolts to specified torque.

Tightening torque
Automatic transmission breather pipe bolt (a):
5.5 N·m (0.55 kgf-m, 4.0 lb-ft)

105)After applying A/T fluid to new O-rings and then

install them to output shaft speed sensor (1) and
input shaft speed sensor (2).

106)Install output shaft speed sensor (1) and input shaft

speed sensor (2).
Tighten transmission speed sensor bolts to specified
torque.

Tightening torque
Transmission speed sensor bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)

107)Apply A/T fluid to new 4 union gaskets and then

install oil cooler pipes (1).
Tighten 2 oil cooler pipe union bolts to specified
torque.

Tightening torque
Oil cooler pipe union bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)

1

(b)

2, (a)

3, (b)

I4JA01512292-01

(a)

1

I4JA01512293-01

2

(a)

(a)

1

I5JA01512005-01

1

(a)

I6JB01510044-01

Automatic Transmission/Transaxle: 5A-153

108)Install transmission range sensor (1) and tighten

transmission range sensor bolt (4) temporarily.

109)Install grommet, lock washer (2) and nut (3).

Tighten nut to specified torque. After tightening it,
bend claws of lock washer.

Tightening torque
Manual shift shaft nut (a): 7 N·m (0.7 kgf-m, 5.0
lb-ft)

110)After turning manual lever shaft fully

counterclockwise, turn it clockwise by 2 notches and
set it to “N” range.

111)With neutral reference line (5) and groove (6) in

transmission range sensor aligned.
Tighten transmission range sensor bolt (4) to
specified torque.

Tightening torque
Transmission range sensor bolt (b): 13 N·m (1.3
kgf-m, 9.5 lb-ft)

112)Install manual select lever (1).

Tighten manual select laver nut (2) to specified
torque.

Tightening torque
Manual select lever nut (a): 12.5 N·m (1.25 kgf-
m, 9.0 lb-ft)

113)Install torque converter (1) to input shaft.

CAUTION

!

Install torque converter, using care not to
damage oil seal lip of oil pump.

(b)

5

6

2

4

1

3, (a)

I5JA01512006-01

1

2, (a)

I6JB01510045-01

1

I4JA01512298-01

5A-154 Automatic Transmission/Transaxle:

Automatic Transmission Unit Assembly
Inspection

S6JB0B5106041

• Hold reverse clutch hub (1), and turn one-way No.2

clutch assembly (2).
Check that one-way No.2 clutch assembly (2) can be
turned freely (3) clockwise and locked (4)
counterclockwise.

• Check that sliding surfaces of discs, plate and flange

are not worn or burnt. If necessary replace them.

NOTE

• If disc lining is exfoliated, discolored or

worn hardly, replace all discs.

• If only a part of printed numbers is

corroded, replace all discs.

• Before assembling new discs, soak them

in A/T fluid for at least 15 minutes.

• Measure free length of 2nd (No.3) brake piston return

spring including spring seat.

2nd (No.3) brake piston return spring free length
“a”: 15.72 mm (0.619 in.)

NOTE

• Do not apply excessive force when

measuring spring free length.

• Perform measurement at several points.

• Measure planetary pinion gear thrust clearance by

using thickness gauge.
If clearance exceeds limit, replace front planetary gear
assembly.

Front planetary pinion gear thrust clearance
Standard: 0.20 – 0.60 mm (0.008 – 0.024 in.)
Limit: 0.65 mm (0.026 in.)

1

4

3

2

I4JA01512299-01

I4JA01512300-01

“a”

I4JA01512301-01

I4JA01512302-01

Automatic Transmission/Transaxle: 5A-155

• Measure inside diameter of front planetary gear

assembly bushing.
If inside diameter exceeds limit, replace front
planetary gear assembly.

Front planetary gear assembly bushing inside
diameter limit
57.48 mm (2.263 in.)

• Install one-way No.1 clutch assembly (1) to one-way

No.1 clutch inner race (2).
Hold one-way No.1 clutch inner race (2), and turn
one-way No.1 clutch assembly (1).
Check that one-way No.1 clutch assembly (1) can be
turned freely (3) counterclockwise and locked (4)
clockwise.
Remove one-way No.1 clutch assembly (1) from one-
way No.1 clutch inner race (2).

• Measure free length of No.1 brake piston return spring

including spring seat.

No.1 brake piston return spring free length
“a”: 17.05 mm (0.671 in.)

NOTE

• Do not apply excessive force when

measuring spring free length.

• Perform measurement at several points.

• Measure free length of No.2 brake piston return spring

including spring seat.

No.2 brake piston return spring free length
“a”: 17.45 mm (0.687 in.)

NOTE

• Do not apply excessive force when

measuring spring free length.

• Perform measurement at several points.

I4JA01512303-01

3

4

2

1

I4JA01512304-01

“a”

I4JA01512305-01

“a”

I4JA01512306-01