Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 333

5A-123 Automatic Transmission/Transaxle:

• Install direct clutch assembly (1) to center support (2)

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

2

, 57 – 113 psi) applied to oil hole (3), measure

stroke of direct clutch piston as shown in the figure.
If it is not within standard range, select another plate
with suitable thickness from the list below and replace
it.

Direct clutch piston standard stroke
0.90 – 1.30 mm (0.035 – 0.051 in.)

Direct Clutch Inspection

S6JB0A5106044

• Measure inside diameter of direct clutch cylinder

bushing. If inside diameter exceeds limit, replace
direct clutch cylinder.

Direct clutch cylinder bushing inside diameter
standard
23.062 – 23.088 mm (0.9080 – 0.9090 in.)

Direct Clutch Piston Return Spring
• Measure free length.

Standard free length of direct clutch piston return
spring
24.25 mm (0.955 in.)

Direct Clutch Piston
• Shake piston to check that ball is not stuck.
• Apply air pressure and check that there is no leakage.

Clutch Disc and Plate
Check that sliding surface of discs and plate 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.

Identification No.

Thickness

No identification

3.925 – 4.050 mm

(0.155 – 0.159 in.)

“B”

3.675 – 3.800 mm

(0.145 – 0.150 in.)

“A”

3.475 – 3.600 mm

(0.137 – 0.142 in.)

2

3

1

I5JB0A510113-01

I5JB0A510156-01

I5JB0A510171-01

IYSQ01510163-01

I4JA01512210-01

Automatic Transmission/Transaxle: 5A-124

Center Support Components

S6JB0A5106045

1

3

4

5

8

11

4

5

9

15

14

9

9

2

FLD

2

FLD

10

FLD

10

FLD

6

FLD

7

FLD

13

FLD

12

FLD

I5JB0A510116-02

1. Center support

6. Second coast brake plate

11. Second brake piston

: Do not reuse.

2. O-ring

7. Second coast brake disc

12. Second brake plate

: Apply A/T fluid.

3. Second coast brake piston

8. Clutch backing plate

13. Second brake disc

4. Piston return spring

9. Retaining ring

14. Planetary sun gear

5. Snap ring

10. Seal ring

15. Second brake hub assembly

5A-125 Automatic Transmission/Transaxle:

Center Support Disassembly and Assembly

S6JB0A5106046

Disassembly

1) Remove retaining ring.

Special tool
(A): 09920–76010

2) Pull out center support assembly (2) from planetary

sun gear (1).

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

2

,

57 – 113 psi) to oil hole (1) at the extreme left and
measure movement of second coast brake (Second
coast brake) piston.
If measured value is not within standard range,
replace second coast brake plate or second coast
brake disc.

Standard second coast brake piston movement
0.75 – 1.35 mm (0.030 – 0.053 in.)

4) Remove retaining ring.

5) After removing clutch backing plate (1), remove

second coast brake plate (3) and second coast
brake disc (2).

6) Using special tool and hydraulic press, compress

piston return spring and remove snap ring.

CAUTION

!

Be careful when applying pressure, for
overpressure will cause plate section of
piston return spring to deform.

Special tool
(A): 09926–98310

7) Remove brake piston return spring (1).

IYSQ01510165-01

1

2

I5JB0A510117-01

1

I5JB0A510118-01

IYSQ01510168-01

2

3

1

I5JB0A510119-02

IYSQ01510170-01

IYSQ01510171-01

Automatic Transmission/Transaxle: 5A-126

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

2

,

57 – 113 psi) to oil hole at the extreme left and
remove second coast brake piston as shown in the
figure. Then remove piston inner O-ring and piston
outer O-ring from second coast brake piston.

9) Remove 3 seal rear rings (1).

NOTE
Use care not to open ring more than
necessary.

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

2

,

57 – 113 psi) to second hole (1) from the left and
measure stroke of second brake (Second brake)
piston as shown in the figure.
If measured value is not within standard range,
replace second brake plate or second brake disc.

Standard second brake piston stroke
0.97 – 1.70 mm (0.038 – 0.067 in.)

11) After removing retaining back plate ring, remove

clutch backing plate, second brake plates and
second brake discs.

12) Using special tool and hydraulic press, compress

brake piston return spring and remove snap second
coast brake ring.

CAUTION

!

Be careful when applying pressure, for
overpressure will cause plate section of
piston return spring to deform.

Special tool
(A): 09926–98310

13) Remove brake piston return spring.

IYSQ01510172-01

IYSQ01510173-01

1

I5JB0A510120-01

IYSQ01510175-01

IYSQ01510176-01

IYSQ01510177-01