Suzuki Grand Vitara JB416 / JB420. Manual — part 243

5A-106 Automatic Transmission/Transaxle:

Overdrive (Planetary Gear Side) Components

S5JB0A5106071

Overdrive (Planetary Gear Side) Disassembly
and Assembly

S5JB0A5106072

Disassembly

1) With overdrive (O/D) clutch cylinder (1) held

stationary, turn O/D input shaft (2) clockwise to
check that it turns smoothly and then
counterclockwise to check that it locks.

12

7

6

4

3

1

1

14

14

8

11

11

15

14

13

11

2

5

FLD

9

FLD

10

FLD

I5JB0A510096-02

1. Bearing

5. O-ring

9. Clutch plate

13. One-way clutch

: Apply A/T fluid.

2. Race

6. Return spring

10. Clutch disc

14. Thrust washer

3. Clutch cylinder

7. Snap ring

11. Retaining ring

15. O/D planetary gear

4. Clutch piston

8. Cushion clutch plate

12. Brake hub

: Do not reuse.

[A]: Rotates
[B]: Locks

IYSQ01510120-01

Automatic Transmission/Transaxle: 5A-107

2) Remove O/D planetary gear assembly (1).

3) With O/D clutch assembly (2) installed to oil pump,

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

2

,

57 – 113 psi) to oil hole (3) in oil pump (1) and
measure stroke of clutch piston. If it is not within
standard range, replace cushion clutch plate or
clutch disc.

Standard stroke of clutch piston
1.74 – 2.44 mm (0.069 – 0.096 in.)

4) Remove retaining ring (1) and then remove brake

hub (2).

5) Remove retaining ring (1) cushion plate (2), clutch

plate (3) and clutch disc (4) in that order.

6) With clutch piston return spring compressed with

special tools, remove clutch piston return spring.

Special tool
(A): 09918–48211
(B): 09926–98320
(C): 09918–48220

7) Install O/D clutch cylinder to oil pump (2). Apply

compression air into fluid hole (3) in oil pump (2) and
remove clutch piston (1).

8) Remove piston inner O-ring and piston outer O-ring

from clutch piston (1).

9) Remove retaining ring from O/D planetary gear and

then remove one-way clutch, thrust washer and
thrust bearing.

2. O/D clutch cylinder

IYSQ01510121-01

2

3

1

I5JB0A510097-01

1

2

I5JB0A510098-01

1

4

3

2

I5JB0A510099-01

1. Snap ring

(C)

1

(A)

(B)

I5JB0A510100-01

1

2

3

I5JB0A510101-01

IYSQ01510127-01

5A-108 Automatic Transmission/Transaxle:

Assembly
Assemble each component by reversing removal
procedure and noting the following points.
• When installing thrust washer (1), bring its oil groove

(3) to the front.

• When installing one-way clutch to one-way clutch

outer race, bring its flange (2) to the front.

• Before installing piston inner O-ring and piston outer

O-ring, apply A/T fluid to them.

• Install so that snap opening and projection (1) of

clutch piston return spring will not match.

• Install retaining clutch ring and retaining brake hub so

that their slots (2) will not match with dent (1) in O/D
clutch cylinder.

• For installing cushion clutch plate (1), refer to the

figure.

Overdrive (Planetary Gear Side) Inspection

S5JB0A5106073

• 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.

• Check that ball valve of clutch piston is not stuck.
• Check valve for leakage by applying low pressure air

into ball valve hale.

[A]: Front

2. Slot

I5JB0A510154-02

IYSQ01510129-01

IYSQ01510130-01

2. Clutch cylinder side
3. Brake hub side

IYSQ01510131-01

I4JA01512210-01

IYSQ01510132-01

Automatic Transmission/Transaxle: 5A-109

• Measure free length of piston return spring.

Standard free length of O/D clutch piston return
spring
16.9 mm (0.665 in.)

• Measure inside diameter of planetary gear bushing. If

inside diameter exceeds limit, replace planetary gear.

Planetary gear bushing inside diameter standard
11.200 – 11.221 mm (0.4409 – 0.4418 in.)

Overdrive (Case Side) Components

S5JB0A5106074

I5JB0A510171-01

I5JB0A510149-01

1

FLD

13

FLD

12

FLD

6

FLD

8

7

9

5

2

3

4

3

2

10

11

10

I5JB0A510103-01

1. Sealing

4. O/D case

7. Brake piston

10. Retaining ring

13. Brake plate

2. Bearing

5. Planetary ring gear

8. Return spring

11. Brake backing plate

: Do not reuse.

3. Bearing race

6. O-ring

9. Thrust washer

12. Brake disc

: Apply A/T fluid.