Suzuki Grand Vitara JB416 / JB420. Manual — part 244

5A-110 Automatic Transmission/Transaxle:

Overdrive (Case Side) Disassembly and
Assembly

S5JB0A5106075

Disassembly

1) Remove retaining ring (1), brake backing plate (2),

brake disc (3) and brake plate (4) in that order. Then
remove planetary ring gear, thrust bearing race and
thrust bearing.

2) Remove retaining ring and piston return spring using

special tool and press (1).

Special tool
(A): 09926–96510

CAUTION

!

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

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

2

,

57 – 113 psi) to oil hole (1) in O/D case (2) and
remove brake piston.

4) Remove brake piston inner ring and brake piston

outer ring from brake piston.

5) Unsnap seal ring (1).
6) Remove 2 seal rings (1).

NOTE
Be careful not to open seal ring more than
necessary.

1

2

3

4

I5JB0A510104-01

1

(A)

I5JB0A510105-01

1

2

I5JB0A510106-01

IYSQ01510138-01

Automatic Transmission/Transaxle: 5A-111

Assembly
Install each component by reversing removal procedure
and noting the following points.
• When installing rear seal ring, use care not to open it

too wide.

• Apply A/T fluid to O-ring, disc, etc. before installing

them.

• Opening of retaining brake front ring (2) and

projection (1) of O/D case should be matched.

• When installing each component, refer to “Overdrive

(Case Side) Components”.

• Measure clearance between retaining ring (1) and

brake backing plate (2) with thickness gauge.
If the clearance is out of specification, select another
plate with suitable thickness from the list below and
replace it.

Standard clearance between retaining ring and
brake backing plate
0.40 – 1.38 mm (0.016 – 0.054 in.)

Overdrive (Case Side) Inspection

S5JB0A5106076

• Measure free length of piston return spring.

Standard free length of O/D brake piston return
spring
15.10 mm (0.594 in.)

• 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.

Thickness

1.95 – 2.05 mm (0.077 – 0.081 in.)
2.25 – 2.35 mm (0.089 – 0.093 in.)

IYSQ01510139-01

IYSQ01510134-01

I5JB0A510171-01

I4JA01512210-01

5A-112 Automatic Transmission/Transaxle:

Forward Clutch Components

S5JB0A5106077

Forward Clutch Disassembly and Assembly

S5JB0A5106078

Disassembly

1) After removing retaining ring (1), remove direct

clutch hub (2) and forward clutch hub (3).

2) Remove bearing race (1) and thrust bearing (2).

3) Remove retaining ring (1) and then remove all clutch

discs.

1

2

3

4

5

5

5

6

7

8

9

10

11

FLD

FLD

FLD

I5JB0A510108-01

1. Input shaft

5. Retaining ring

9. Clutch disc

: Apply A/T fluid.

2. Piston

6. Bearing race

10. Froward clutch hub

3. Return spring

7. Bearing

11. Direct clutch hub

4. O-ring

8. Clutch plate

: Do not reuse.

IYSQ01510143-01

I5JB0A510109-01

IYSQ01510147-01

Automatic Transmission/Transaxle: 5A-113

4) Using special tool and hydraulic press, compress

forward clutch piston return spring and remove
retaining return spring.

Special tool
(A): 09926–98310

CAUTION

!

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

5) Remove forward clutch piston return spring.

6) Install forward clutch to O/D case (1). Blow low

pressure air into fluid hole (2) at the right of cut in O/
D case to remove forward clutch piston (3).

Assembly

1) Apply A/T fluid to forward input shaft O-rings, install

forward clutch piston and piston return spring (2) to
forward input shaft and then install return spring ring
with special tool and hydraulic press.

Special tool
(A): 09926–98310

NOTE

• When installing return spring (2), be

careful so that return spring will not fall or
tilt.

• Do not align opening in retaining ring (1)

with lug of forward clutch piston return
spring at its retainer section.

CAUTION

!

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

2) Install clutch discs and plates and then install

retaining clutch ring.

NOTE

• Refer to “Forward Clutch Components”

when installing each component.

• Do not match opening in retaining clutch

ring and dent in forward clutch input shaft.

3) Install bearing races (1) and thrust bearing (2).

IYSQ01510148-01

I5JB0A510110-01

IYSQ01510150-01

I5JB0A510111-01