Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 302

from battery, TCM ground wire harness from engine or
main fuse before checking the diagnostic information
(DTC, freeze frame data, etc.) stored in TCM memory.
Such disconnection will clear memorized information
in TCM memory.

• For E-OBD model, diagnostic information stored in

TCM memory can be cleared as well as checked by
using SUZUKI scan tool or OBD generic scan tool.
Before using scan tool, read its Operator’s
(Instruction) Manual carefully to have good
understanding as to what functions are available and
how to use it.
It is indistinguishable which module turns on MIL
because not only ECM but also TCM turns on MIL.
Therefore, check both ECM and TCM for DTC when
MIL lights on.
When checking TCM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– OBD generic scan tool displays DTC detected by

each of ECM and TCM simultaneously.

• For non-E-OBD model, using SUZUKI scan tool the

diagnostic information stored in TCM memory can be
checked and cleared as well. Before its use, be sure
to read Operator’s Manual supplied with it carefully to
have good understanding of its functions and usage.

• Be sure to read “Precautions for Electrical Circuit

Service in Section 00” before inspection and observe
what is written there.

• TCM and/or ECM replacement:

When substituting a known-good TCM and/or ECM,
check for the following conditions.
Neglecting this check may result in damage to a good
TCM and/or ECM.
– All relays and actuators have resistance of

specified value.

– MAF sensor, Manifold absolute pressure (MAP)

sensor, TP sensor and fuel tank pressure sensor
are in good condition. Also, the power circuit of
these sensors is not shorted to the ground.

• Communication of ECUs, ECM, TCM, BCM,

combination meter, 4WD control module (if equipped),
ABS/ESP

® control module, keyless start control

module (if equipped), steering angle sensor (if
equipped) and DLC is established by CAN (controller
Area Network). For more detail of CAN
communication, refer to “CAN Communication
System Description”. Therefore, handle CAN
communication line with care referring to “Precaution
for CAN Communication System in Section 00”.

General Service Procedure Information

S6JB0A5100002

When repairing automatic transmission, it is necessary
to conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is
determined. If the transmission is disassembled without
such preliminary procedure, not only the cause of the
trouble would be unknown, but also a secondary trouble
may occur and often time would be wasted.

Automatic Transmission/Transaxle: 5A-2

Precautions for Disassembly and Reassembly

S6JB0A5100003

As the automatic transmission consists of high precision
components, the following cautions should be strictly
observed when handling its parts in disassembly and
reassembly.
• Disassembling valve body assembly is prohibited in

principle. However, a few parts can be disassembled.
When disassembling valve body component parts,
confirm whether these parts are allowed to
disassemble or not referring to “Valve Body Assembly
Components”.

• Make sure to wash dirt off from the transmission so

that no such dirt will enter the transmission during
dismounting and remounting.

• Select a clean place free from dust and dirt for

overhauling.

• Place a rubber mat on the work bench to protect parts

from damage.

• Work gloves or shop cloth should not be used. (Use

nylon cloth or paper towel.)

• When separating the case joint, do not pry with a

screwdriver or such but tap with a plastic hammer
lightly.

• Wash the disassembled parts in ATF (Automatic

Transmission Fluid) or kerosene (using care not to
allow ATF or kerosene to get on your face, etc.) and
confirm that each fluid passage is not clogged by
blowing air into it. But use ATF to wash the disc, resin
washers and rubber parts.

• Replace each gasket, oil seal and O-ring with a new

one.

• Apply ATF to sliding or rotating parts before

reassembly.

• A new disc should be soaked in ATF at least 2 hours

before use.

Part Inspection and Correction Table

Part

Inspect for

Correction

Casted part, machined part Small flaw, burr

Remove with oil stone.

Deep or grooved flaw

Replace part.

Clogged fluid passage

Clean with air or wire.

Flaw on installing surface, residual gasket

Remove with oil stone or replace part.

Crack

Replace part.

Bearing

Unsmooth rotation

Replace.

Streak, pitting, flaw, crack

Replace.

Bushing, thrust washer

Flaw, burr, wear, burning

Replace.

Oil seal, gasket

Flawed or hardened seal ring

Replace.

Worn seal ring on its periphery or side

Replace.

Piston seal ring, oil seal, gasket, etc.

Replace.

Gear

Flaw, burr

Replace.

Worn gear tooth

Replace.

Splined part

Burr, flaw, torsion

Correct with oil stone or replace.

Snap ring

Wear, flaw, distortion

Replace.

No interference

Replace.

Thread

Burr

Replace.

Damage

Replace.

Spring

Settling, sign of burning

Replace.

Clutch disc, brake disc

Wear, burning, distortion, damaged claw

Replace.

Clutch plate, brake plate

Wear, burning, distortion, damaged claw

Replace.

Sealing surface (where lip
contacts)

Flaw, rough surface, stepped wear, foreign
material

Replace.

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Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 302

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