Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 336

5A-135 Automatic Transmission/Transaxle:

13) After confirming that lugs of all brake plates and

brake discs are in grooves securely, hold retaining
ring (1) of planetary sun gear, install center support
assembly by aligning bolt holes (2) in center support
and transmission case.

NOTE
Unless retaining ring of planetary sun gear is
held, brake valve gets off center support and
that will make it impossible to align fluid
holes with bolt holes.

14) Tighten center support bolts by certain amount at a

time till specified tightening torque is obtained.

Tightening torque
Center support bolt: 26 N·m (2.6 kgf-m, 19.0 lb-
ft)

15) Install direct clutch assembly by aligning splines in

direct clutch cylinder with planetary sun gear.

NOTE
Ends of splines in direct clutch cylinder and
planetary sun gear should come almost in
match.

16) Apply grease to thrust bearing (1) and bearing races

(2), and then install them to direct clutch.

17) Install forward clutch assembly by putting all lugs of

direct clutch disc hub together and matching them
with groove cut in direct clutch input hub, and at the
same time aligning splines in forward clutch hub with
inner shaft.

NOTE
Use care not to let forward clutch rear No.1
race and thrust bearing installed to forward
clutch hub fall off.

1

2

I5JB0A510133-01

IYSQ01510246-01

IYSQ01510247-01

2

1

I5JB0A510134-01

IYSQ01510249-01

Automatic Transmission/Transaxle: 5A-136

18) When clutch disc and plate have been replaced,

check height difference between forward clutch input
shaft and transmission case (1) by measuring as
shown in the figure.

NOTE
If measured value is less than standard
value, remove forward clutch assembly and
install it again.

Standard height difference between forward
clutch input shaft and transmission case
“a”: About 2.0 mm (0.079 in.)

19) Apply grease to thrust bearing (1) and bearing race

(2), and then install them to forward clutch input
shaft.

20) Install O/D case by aligning cutout in O/D case (1)

and that in transmission case.

NOTE
Use care not to drop thrust rear race installed
to O/D case.

21) Apply grease to thrust washers (1) and install them

to O/D planetary gear (2) and planetary ring gear (3),
and then install O/D input shaft assembly to O/D
case.

NOTE

• Fit claws of thrust washer into holes

securely.

• Use care not to drop thrust washer

installed to O/D planetary gear.

22) When clutch disc or plate has been replaced, check

height difference between O/D case (1) and O/D
clutch cylinder (2) by measuring it as shown in the
figure.

NOTE
Measure at the highest point along inner
circumference of O/D clutch cylinder.

Standard height difference between O/D case
and O/D clutch cylinder
“a”: About 3.5 mm (0.138 in.)

2. Forward clutch

2. Cutout in automatic transmission

2

1

“a”

I5JB0A510135-01

2

1

I5JB0A510136-01

1

2

I5JB0A510137-02

I5JB0A510138-01

I5JB0A510161-01

5A-137 Automatic Transmission/Transaxle:

23) Apply A/T fluid to new housing O-ring and install it to

O/D case. Then install converter housing (1) and
tighten housing bolt to specified torque.

Tightening torque
Torque converter housing bolt (a): 35 N·m (3.5
kgf-m, 25.5 lb-ft)
Torque converter housing bolt (b): 58 N·m (5.8
kgf-m, 42.0 lb-ft)

24) Apply grease to bearing race (1) and thrust bearing

(2) and install them to O/D clutch cylinder.

25) Apply A/T fluid to new oil pump cover O-ring and

install it to oil pump assembly. Then install oil pump
assembly aligning bolt holes in O/D case with those
in transmission case oil pump assembly. Apply seal
packing to oil pump assembly bolts and tighten them
by certain amount of torque at each time one after
another till specified torque is attained.

Tightening torque
Oil pump bolt (a): 22 N·m (2.2 kgf-m, 16.0 lb-ft)

26) Apply 2 – 4 kg/cm

2

air pressure into fluid holes in the

figure as numbered and check operation sound of
each part.

27) Take down transmission from stand and install new

gasket and cover plate (1).

28) Measure clearance in shaft direction by applying dial

gauge (1) to output shaft as shown in the figure.

Standard clearance in shaft direction
0.3 – 0.9 mm (0.012 – 0.035 in.)

I5JB0A510162-01

1

2

I5JB0A510139-01

IYSQ01510257-01

1. O/D clutch

5. Second coast brake

2. O/D brake

6. Second brake

3. Forward clutch

7. Reverse brake

4. Direct clutch

IYSQ01510258-01

1

I5JB0A510089-01

IYSQ01510259-01

Automatic Transmission/Transaxle: 5A-138

29) Check that inner shaft runs smoothly.
30) Apply grease to lip of new oil lip seal and drive in oil

lip seal with special tool till it contacts transmission
case.

Special tool
(A): 09923–46020

31) Install a new spacer (1) to manual shift lever (2).
32) Install manual shift shaft (3) to transmission case

through manual shift lever.

33) Drive in manual shift lever pin (1) by using hammer.

34) Align hole in sleeve cover with dent in manual shift

lever and caulk securely with pin punch (1). Then
check that manual shift shaft turns smoothly.

35) Install parking lock pawl (2), parking pawl pin (1) and

parking pawl spring (3).

36) Connect parking lock rod (2) to manual shift lever (1)

as shown in the figure.

37) Install parking lock pawl bracket (1).

Tighten parking pawl bracket bolts (2) to specified
torque.

Tightening torque
Parking pawl bracket bolt (a): 7.4 N·m (0.74 kgf-
m, 5.5 lb-ft)

IYSQ01510261-01

2

1

3

I4JA01512266-01

1

I4JA01512267-01

1

I4JA01512268-01

2

1

3

I4JA01512269-01

1

2

I4JA01512270-01

1

2, (a)

I4JA01512271-01