Suzuki Grand Vitara JB416 / JB420. Manual — part 216
5-ii Table of Contents
DTC P0973 / P0976: Shift Solenoid “A”
Control Circuit Low / Shift Solenoid “B”
Control Circuit Low. . . . . . . . . . ..5A-59
DTC P0974 / P0977: Shift Solenoid “A”
Control Circuit High / Shift Solenoid “B”
Control Circuit High . . . . . . . . . . .5A-61
DTC P1702: Internal Control Module Memory
Check Sum Error . . . . . . . . . . . 5A-62
DTC P1703: CAN Invalid Data - TCM. . . ...5A-62
DTC P1723: Range Select Switch
Malfunction. . . . . . . . . . . . . ..5A-63
DTC P1774: CAN Communication Bus Off. ...5A-64
DTC P1777: TCM Lost Communication with
ECM (Reception Error) . . . . . . . . ...5A-66
DTC P1778: TCM Lost Communication with
BCM (Reception Error) . . . . . . . . ...5A-67
DTC P1874: 4L Switch Circuit Malfunction
(Short) . . . . . . . . . . . . . . . .5A-68
DTC P1875: 4L Switch Circuit Malfunction
(Open) . . . . . . . . . . . . . . . .5A-69
DTC P1878: Torque Converter Clutch
Shudder . . . . . . . . . . . . . . ..5A-71
DTC P2763: Torque Converter Clutch (TCC)
Circuit High . . . . . . . . . . . . . .5A-71
DTC P2764: Torque Converter Clutch (TCC)
Circuit Low . . . . . . . . . . . . . ..5A-73
Inspection of TCM and Its Circuits . . . . . 5A-74
TCM Power and Ground Circuit Check. . . .5A-78
Repair Instructions . . . . . . . . . . . 5A-80
A/T Fluid Level Check . . . . . . . . . ...5A-80
A/T Fluid Change . . . . . . . . . . . ..5A-81
Manual Selector Assembly Components . . ..5A-81
Manual Selector Assembly Removal and
Installation. . . . . . . . . . . . . ...5A-82
Select Lever Knob Installation. . . . . . ...5A-82
Manual Selector Assembly Inspection . . . ..5A-82
“3” Position Switch Inspection . . . . . . ...5A-82
Select Cable Component . . . . . . . . ..5A-83
Select Cable Adjustment. . . . . . . . ...5A-83
Transmission Range Sensor Removal and
Installation. . . . . . . . . . . . . ...5A-84
Transmission Range Sensor Inspection and
Adjustment . . . . . . . . . . . . . ..5A-84
Key Interlock Cable Removal and Installation...5A-85
Brake and key Interlock System Inspection . ..5A-87
Mode Select Switch Inspection . . . . . . .5A-88
Input Shaft Speed Sensor Removal and
Installation. . . . . . . . . . . . . ...5A-88
Input Shaft Speed Sensor Inspection. . . . 5A-89
Output Shaft Speed Sensor Removal and
Installation. . . . . . . . . . . . . ...5A-89
Output Shaft Speed Sensor Inspection. . . .5A-89
Oil Cooler Hose and Pipe Components . . . 5A-90
Oil Cooler Hose and Pipes Removal and
Installation. . . . . . . . . . . . . ...5A-90
Solenoid Valves (Shift Solenoid-A, Shift
Solenoid Valves (Shift Solenoid-A, Shift
Solenoid-B, TCC Pressure Control Solenoid
and Pressure Control Solenoid Inspection. ..5A-92
Transmission Fluid Temperature Sensor
Removal and Installation. . . . . . . . .5A-93
Transmission Fluid Temperature Sensor
Inspection. . . . . . . . . . . . . . 5A-94
Transmission Control Module (TCM)
Removal and Installation. . . . . . . . .5A-95
A/T Relay Inspection . . . . . . . . . . .5A-95
Automatic Transmission Unit Components . ...5A-96
Automatic Transmission Assembly
Dismounting and Remounting. . . . . . .5A-97
Automatic Transmission Unit Disassembly . ...5A-98
Oil Pump Components . . . . . . . . . 5A-103
Oil Pump Disassembly and Assembly . . . 5A-104
Oil Pump Inspection . . . . . . . . . . 5A-104
Overdrive (Planetary Gear Side) Components 5A-106
Overdrive (Planetary Gear Side) Disassembly
and Assembly. . . . . . . . . . . . 5A-106
Overdrive (Planetary Gear Side) Inspection ...5A-108
Overdrive (Case Side) Components . . . ...5A-109
Overdrive (Case Side) Disassembly and
Assembly. . . . . . . . . . . . . ...5A-110
Overdrive (Case Side) Inspection . . . . ...5A-111
Forward Clutch Components . . . . . . ..5A-112
Forward Clutch Disassembly and Assembly...5A-112
Forward Clutch Inspection . . . . . . . ..5A-114
Direct Clutch Components . . . . . . . ..5A-115
Direct Clutch Disassembly and Assembly. ...5A-115
Direct Clutch Inspection . . . . . . . . ..5A-117
Center Support Components . . . . . . ..5A-118
Center Support Disassembly and Assembly...5A-119
Center Support Inspection . . . . . . . ..5A-122
Planetary Gears and Output Shaft
Components. . . . . . . . . . . . ..5A-123
Planetary Gears and Output Shaft
Disassembly and Assembly . . . . . . ..5A-124
Planetary Gears and Output Shaft Inspection.5A-125
Valve Body Assembly Components . . . . 5A-126
Automatic Transmission Unit Assembly. . ..5A-126
Specifications . . . . . . . . . . . . ...5A-135
Bearing and Race Installation Diagram. . ...5A-135
Tightening Torque Specifications. . . . . 5A-136
Special Tools and Equipment . . . . . . .5A-137
Recommended Service Material . . . . . .5A-137
Special Tool . . . . . . . . . . . . . 5A-137
Manual Transmission/Transaxle . . . 5B-1
General Description . . . . . . . . . . . .5B-1
Manual Transmission Construction. . . . . .5B-1
Diagnostic Information and Procedures . . . 5B-2
Manual Transmission Symptom Diagnosis . . .5B-2
Repair Instructions . . . . . . . . . . . ..5B-3
Manual Transmission Assembly Components . 5B-3
Gear Shift Control Lever Rear Case
Assembly Components . . . . . . . . . .5B-5
Table of Contents 5-iii
Gear Shift Shaft and Fork Components. . . .. 5B-7
Input Shaft Assembly, Output Shaft Assembly
and Countershaft Assembly Components . . 5B-8
Manual Transmission Oil Change . . . . . ... 5B-9
Transmission Shift Control Lever Removal
and Installation. . . . . . . . . . . . 5B-10
Transmission Shift Control Lever Inspection. .5B-10
Back Up Light Switch Removal and
Installation. . . . . . . . . . . . . ...5B-11
Back Up Light Switch Inspection. . . . . ... 5B-11
Gear Shift Control Lever Rear Case
Assembly Removal and Installation . . . . 5B-11
Gear Shift Control Lever Rear Case
Assembly Disassembly and Reassembly . ... 5B-12
Gear Shift Control Lever Rear Case
Assembly Inspection . . . . . . . . . ... 5B-12
Gear Shift Lever Front Case Assembly
Removal and Installation. . . . . . . . . 5B-12
Gear Shift Lever Front Case Assembly
Disassembly and Reassembly. . . . . . 5B-13
Gear Shift Lever Front Case Assembly
Inspection. . . . . . . . . . . . . . 5B-14
Engine Rear Mounting Replacement . . . . 5B-14
Manual Transmission Assembly Dismounting
and Remounting. . . . . . . . . . . .. 5B-14
Manual Transmission Unit Disassembly . . ... 5B-17
Manual Transmission Unit Reassembly. . . 5B-18
Locating Spring Inspection. . . . . . . . 5B-21
Input Shaft Disassembly . . . . . . . . ...5B-21
Input Shaft Inspection . . . . . . . . . ... 5B-22
Input Shaft Reassembly. . . . . . . . . 5B-23
Countershaft Disassembly and Assembly. . .5B-25
Countershaft and Reverse Idle Gear
Inspection. . . . . . . . . . . . . . 5B-28
Output Shaft Disassembly and Assembly . . .5B-29
Output Shaft Inspection . . . . . . . . . 5B-29
Manual Transmission Front Case
Disassembly and Assembly . . . . . . . 5B-30
Manual Transmission Adapter Case
Disassembly and Assembly . . . . . . . 5B-30
Specifications. . . . . . . . . . . . . .5B-31
Tightening Torque Specifications. . . . . ..5B-31
Special Tools and Equipment . . . . . . ...5B-31
Recommended Service Material . . . . . ...5B-31
Special Tool . . . . . . . . . . . . . ..5B-32
Clutch . . . . . . . . . . . . . ... 5C-1
General Description . . . . . . . . . . . .5C-1
Clutch (Hydraulic Type) Construction . . . . .5C-1
Component Location . . . . . . . . . . ...5C-2
Clutch Fluid Pipe and Hose Location . . . . ..5C-2
Diagnostic Information and Procedures. . . 5C-3
Clutch (Hydraulic Type) Symptom Diagnosis. ..5C-3
Repair Instructions . . . . . . . . . . . ..5C-4
and Installation . . . . . . . . . . . . ..5C-4
Clutch Pedal Position (CPP) Switch
Inspection and Adjustment. . . . . . . . 5C-5
Clutch Fluid Pipe and Hose Removal and
Installation . . . . . . . . . . . . . . .5C-5
Clutch Fluid Pipe and Hose Inspection . . . ...5C-6
Clutch Master Cylinder Removal and
Installation . . . . . . . . . . . . . . .5C-6
Clutch Master Cylinder Inspection . . . . . ..5C-7
Clutch Operating Cylinder Assembly
Removal and Installation. . . . . . . . ...5C-7
Clutch Cover, Clutch Disc and Flywheel
Components. . . . . . . . . . . . . ..5C-8
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation. . . . . . . . ...5C-9
Clutch Cover, Clutch Disc and Flywheel
Inspection. . . . . . . . . . . . . . 5C-10
Specifications. . . . . . . . . . . . . .5C-11
Tightening Torque Specifications. . . . . ..5C-11
Special Tools and Equipment . . . . . . ...5C-11
Recommended Service Material . . . . . ...5C-11
Special Tool . . . . . . . . . . . . . ..5C-11
5-1 Precautions:
Transmission / Transaxle
Precautions
Precautions
Precautions for Transmission / Transaxle
S5JB0A5000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Fastener Caution
Refer to “Fastener Caution in Section 00”.
Precautions in Diagnosing Trouble (for A/T)
Refer to “Precautions in Diagnosing Trouble in Section 5A”.
Precautions for Disassembly and Reassembly (for A/T)
Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Automatic Transmission/Transaxle: 5A-1
Transmission / Transaxle
Automatic Transmission/Transaxle
Precautions
Precautions in Diagnosing Trouble
S5JB0A5100001
• Do not disconnect couplers from TCM, battery cable
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 vehicle without engine diagnosis connector,
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 vehicle with engine diagnosis connector, 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.
• Not using scan tool (if equipped with AT monitor
connector), the DTC stored in TCM memory also can
be checked and cleared. DTC stored in the TCM
memory is outputted by displaying DTC on digital
display odometer with diagnosis terminal of monitor
connector grounded. If no DTC is stored in TCM
memory, DTC 0000 is outputted. If one or more DTCs
are stored in TCM memory, they are outputted starting
from smallest code number in increasing order. After
all DTCs are outputted, all DTCs are outputted
repeatedly.
• 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 ABS
hydraulic unit / control module assembly, and keyless
start control module (if equipped), is established by
CAN (controller Area Network). Therefore, handle
CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
General Service Procedure Information
S5JB0A5100002
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.
Precautions for Disassembly and Reassembly
S5JB0A5100003
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.
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