Suzuki Grand Vitara JB416 / JB420. Manual — part 248

5A-126 Automatic Transmission/Transaxle:

Valve Body Assembly Components

S5JB0A5106087

Automatic Transmission Unit Assembly

S5JB0A5106088

CAUTION

!

When replacing pressure control solenoid
valve and/or TCC pressure control solenoid
valve, it is strictly required to replace it
together with valve body assembly as a set.
Replacing pressure control solenoid valve
and/or TCC pressure control solenoid valve
independently may cause excessive shift
shock.

1) Measure inside diameter of transmission case

bushing. If inside diameter exceeds limit, replace
transmission case.

Transmission case bushing inside diameter
standard
38.113 – 38.138 mm (1.5005 – 1.5015 in.)

2) After applying A/T fluid to new O-rings, install them

to reverse brake piston (3), reaction sleeve (2) and
secondary reverse piston (1).

6

11

5

4

1

8

13

3

2

9

10

7

(a)

11

(a)

(a)

12

(a)

I5JB0A510127-01

1. Manual valve

5. Plate

9. Solenoid clamp

13. Valve body assembly

2. TCC control solenoid valve

6. Shift solenoid valve A

10. Solenoid clamp bolt

: 5.5 N

⋅m (0.55 kgf-m, 4.0 lb-ft)

3. Pressure control solenoid valve

7. Shift solenoid valve B

11. Shift solenoid bolt

4. Detent spring

8. Over drive (O/D) brake apply

tube

12. Detent spring bolt

I5JB0A510129-01

IYSQ01510236-01

Automatic Transmission/Transaxle: 5A-127

3) Measure free length of reverse brake piston return

spring.

Standard free length of reverse brake piston
return spring
16.84 mm (0.663 in.)

4) Install reverse brake piston assembly and brake

piston return spring to transmission case, using care
not to damage O-ring. Then install snap ring (1) with
special tools.

NOTE

• Install so that opening in snap ring (1) will

not align with any of 3 lugs of spring seat.

• Do not compress spring more than

necessary and do not allow it fall or tilt.

Special tool
(A): 09926–98320
(B): 09926–98390
(C): 09944–88210

5) Prepare a stand as shown. It is necessary because

work will be done with transmission case (1) set
upright from this step on.

NOTE

• To protect transmission case against

damage, spread cloth on stand where case
contacts.

• A stand of such size as shown in the figure

will facilitate work.

6) Install thrust bearing (1) and thrust bearing race (2)

after lubricating them with grease.

NOTE
Make sure that thrust bearing output shaft
race is installed in proper direction.

7) Install brake applying tube (1) so that its lug (2) fits in

a in transmission case (4). After installation, check
that 4 lugs (3) along the underside of brake applying
tube fit inside of reverse brake piston.

8) Install leaf spring (1) as shown in figure.

2. Nut M12 x 1.75

A: 50 mm (1.9 in.)

C: 400 mm (15.7 in.)

B: 350 mm (13.8 in.)

D: 200 mm (7.9 in.)

1

2

(C)

(A)

(B)

I5JB0A510128-01

1

C

A

D

B

I5JB0A510079-01

I5JB0A510160-01

2

1

3

4

I5JB0A510130-02

1

I5JB0A510131-02

5A-128 Automatic Transmission/Transaxle:

9) Remove reverse brake reaction plate of planetary

gear assembly and align lugs of reverse brake plate,
reverse brake disc and reverse brake backing plate.
Install planetary gear assembly to transmission case
so that aligned lugs fit in groove in transmission
case.

10) Measure clearance between reverse brake plate and

lugs of transmission case.
If measured value is less than standard range, it is
possible that something is installed improperly or
dust or fluid is on reverse brake disc, etc. If it
exceeds standard range, adjust it to standard
clearance with selective reverse brake backing
plates as shown after making sure reverse brake
disc, reverse brake plate and reverse brake backing
plate are in good condition. If the clearance is out of
specification, select another plate with suitable
thickness from the list below and replace it.

Standard clearance between reverse brake plate
and lugs of transmission case
0.52 – 1.27 mm (0.020 – 0.050 in.)

Available plate thickness

11) Install reverse brake reaction plate so that its lug with

dent (1) comes to specified position as shown in
figure.

12) Using screwdriver with vinyl tape or the like wound at

its tip, install retaining reaction plate ring (1). After
installation, check that ring is in groove securely.

Identification No.

Thickness

No identification

2.95 – 3.05 mm

(0.116 – 0.120 in.)

“325”

3.20 – 3.30 mm

(0.126 – 0.120 in.)

“350”

3.45 – 3.55 mm

(0.136 – 0.140 in.)

“375”

3.70 – 3.80 mm

(0.146 – 0.150 in.)

“400”

3.95 – 4.05 mm

(0.156 – 0.159 in.)

“425”

4.20 – 4.30 mm

(0.165 – 0.169 in.)

IYSQ01510241-01

IYSQ01510242-01

1

I5JB0A510132-01

1

I5JB0A510084-01

Automatic Transmission/Transaxle: 5A-129

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