LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2005 >> Aerio S, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Repair Instructions >> Automatic Transaxle Unit Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Automatic Transaxle Unit Assembly

  1. Apply lithium grease to new manual shift shaft oil seal lip.

    : Grease 99000-25030 

  2. Press-fit new manual shift shaft oil seal (1) to transaxle case, using special tool.

    Special tool 

    (A): 09943-88211 

    Fig 1: Installing Manual Shift Shaft Oil Seal To Transaxle Case
    G04015201Courtesy of SUZUKI OF AMERICA CORP.
  3. Apply A/T fluid to new oil seal rings (1) and install oil seal rings (1) to transaxle case.
    NOTE: Do not spread oil seal ring ends excessively.
    Fig 2: Installing Oil Seal Rings To Transaxle Case
    G04015202Courtesy of SUZUKI OF AMERICA CORP.
  4. Install one-way No. 3 clutch (1) to transaxle case.
    NOTE: Make sure that groove section of one-way No. 3 clutch faces (2) toward upper side.
  5. Install snap ring (3), using flat end rod or the like.
    NOTE: Make sure that opening end of snap ring should be aligned with protrusion of transaxle case.
    Fig 3: Installing Snap Ring
    G04015203Courtesy of SUZUKI OF AMERICA CORP.
  6. Apply A/T fluid to new O-rings (1) and install O-rings (1) to underdrive brake accumulator cover (2) and underdrive brake accumulator piston (3).
  7. Put underdrive brake accumulator spring (4) in transaxle case, and insert under drive brake accumulator piston (3) and underdrive brake accumulator cover (2) into transaxle case.
    NOTE: Do not twist or deviate O-rings during installation.
    Fig 4: Inserting Under Drive Brake Accumulator Piston And Underdrive Brake Accumulator Cover Into Transaxle Case
    G04015204Courtesy of SUZUKI OF AMERICA CORP.
  8. Push underdrive brake accumulator cover and install underdrive brake accumulator bracket (1), spacer (2) and torsion spring (3) by tighten 2 Torx® bolts to specified torque.

    Tightening torque 

    Underdrive brake accumulator bracket bolt(s) 

    (a): 10 N.m (1.0kg-m,7.5 lb-ft) 

    Fig 5: Installing Underdrive Brake Accumulator Bracket, Spacer And Torsion Spring
    G04015205Courtesy of SUZUKI OF AMERICA CORP.
  9. Apply A/T fluid to new O-rings (1) and install O-rings (1) to underdrive brake piston assembly (2) and underdrive brake piston cover (3).
  10. Put underdrive brake piston return spring (4) in transaxle case, and underdrive brake piston assembly (2) and underdrive brake piston cover (3) into transaxle case.
    NOTE: Do not twist or deviate O-rings during installation.
    Fig 6: Installing O-Rings To Underdrive Brake Piston Assembly And Underdrive Brake Piston Cover
    G04015206Courtesy of SUZUKI OF AMERICA CORP.
  11. Apply special tools and push in underdrive brake piston cover (1).

    Special tool 

    (A): 09916-14510 

    (B): 09916-14910 

  12. Install snap ring (2), using pliers or the like.
    Fig 7: Installing Snap Ring
    G04015207Courtesy of SUZUKI OF AMERICA CORP.
  13. Install underdrive brake band (1).
    Fig 8: Installing Underdrive Brake Band
    G04015208Courtesy of SUZUKI OF AMERICA CORP.
  14. Apply A/T fluid to new O-ring (1) and install new O-ring (1) to underdrive brake band anchor bolt (2).
  15. Tighten underdrive brake band anchor bolt (2) to specified torque.

    Tightening torque 

    Underdrive brake band anchor bolt (a): 170 N.m (17.0 kg-m, 123.0 lb-ft) 

  16. Remove oil plug bolt with O-ring installed (3).
    Fig 9: Removing Oil Plug Bolt With O-Ring
    G04015209Courtesy of SUZUKI OF AMERICA CORP.
  17. Measure underdrive brake piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm2 , 57 - 113 psi) through oil hole (2). If measured piston stroke exceeds specified value, replace underdrive brake piston rod in the following so as piston stroke to be in standard value. If piston stroke is still standard value or more, replace underdrive brake band with a new one.

    Underdrive brake piston stroke 

    Standard: 5.48 - 7.02 mm (0.26 - 0.28 in.) 

    Available underdrive brake piston rod length 

    70.5 mm (2.776 in.), 72.0 mm (2.835 in.) 

    Fig 10: Measuring Underdrive Brake Piston Stroke
    G04015210Courtesy of SUZUKI OF AMERICA CORP.
  18. Apply A/T fluid to new O-ring and install O-ring to oil plug bolt (1).
  19. Tighten oil plug bolt to specified torque.

    Tightening torque 

    Underdrive brake oil plug bolt: 7.5 N.m (0.75 kg-m, 5.5 lb-ft) 

    Fig 11: Installing O-Ring To Oil Plug Bolt
    G04015211Courtesy of SUZUKI OF AMERICA CORP.
  20. Apply petroleum jelly to underdrive clutch thrust bearing (1) and countershaft rear thrust bearing race (2).
  21. Install underdrive clutch thrust bearing (1) and countershaft rear thrust bearing race (2) to underdrive clutch assembly (3).
  22. Install underdrive clutch assembly (3) onto transaxle case.
    Fig 12: Installing Underdrive Clutch Assembly Onto Transaxle Case
    G04015212Courtesy of SUZUKI OF AMERICA CORP.
  23. Make sure that underdrive clutch turns freely when turned counterclockwise [A] and locks when turned clockwise [B].
    Fig 13: Checking Underdrive Clutch Operation
    G04015213Courtesy of SUZUKI OF AMERICA CORP.
  24. Apply petroleum jelly to countershaft rear thrust bearing (1), countershaft front thrust bearing (2) and countershaft front thrust bearing race (3).
  25. Install countershaft rear thrust bearing (1), countershaft front thrust bearing race (3) and countershaft front thrust bearing (2) to counter driven gear.
  26. Install underdrive gear assembly (4) onto under drive clutch (5).
    Fig 14: Installing Underdrive Gear Assembly Onto Under Drive Clutch
    G04015214Courtesy of SUZUKI OF AMERICA CORP.
  27. Install parking lock pawl (1). Place torsion spring (2) on parking lock pawl shaft (3) and install them into transaxle case.
  28. Install parking lock pawl bracket and manual detent spring (4) by 2 tightening bolts to specified torque.

    Tightening torque 

    Manual detent spring bolt(s) (a): 10 N.m (1.0 kg-m, 7.5 lb-ft) 

    Fig 15: Installing Parking Lock Pawl
    G04015215Courtesy of SUZUKI OF AMERICA CORP.
  29. Insert parking lock rod (1) to parking lock pawl bracket and connect parking lock rod (1) with manual shift shaft (2).
    Fig 16: Inserting Parking Lock Rod To Parking Lock Pawl Bracket
    G04015216Courtesy of SUZUKI OF AMERICA CORP.
  30. Install reduction drive gear assembly (1) into transaxle case (2).
  31. Install snap ring (3).
    Fig 17: Installing Snap Ring
    G04015217Courtesy of SUZUKI OF AMERICA CORP.
  32. Apply A/T fluid to new O-rings and install O-rings to 1st / reverse brake piston (1).
  33. Place 1st / reverse brake piston (1) into transaxle case.
    NOTE: Do not twist or deviate O-rings during installation.
    Fig 18: Placing 1St / Reverse Brake Piston Into Transaxle Case
    G04015218Courtesy of SUZUKI OF AMERICA CORP.
  34. Mount 1st / reverse brake piston return spring (1).
  35. Install retainer ring (2) by compressing 1st / reverse brake piston return spring (1) with flat end rod or the like.
    NOTE: Make sure that opening end of ring is not aligned with protrusion of transaxle case.
  36. Apply petroleum jelly to front planetary ring gear front thrust bearing race (3).
  37. Place front planetary ring gear front thrust bearing race (3) onto counter driven gear.
    Fig 19: Placing Front Planetary Ring Gear Front Thrust Bearing Race Onto Counter Driven Gear
    G04015219Courtesy of SUZUKI OF AMERICA CORP.
  38. Apply petroleum jelly to front planetary ring gear front thrust bearing (1) and front planetary ring gear rear thrust bearing (2).
  39. Install front planetary ring gear front thrust bearing (1) and front planetary ring gear rear thrust bearing (2) to front planetary ring gear (3).
  40. Install front planetary ring gear (3).
    Fig 20: Installing Front Planetary Ring Gear
    G04015220Courtesy of SUZUKI OF AMERICA CORP.
  41. Make sure that front planetary ring gear (1) turns freely when turned counterclockwise [A] and locks when clockwise [B].
    Fig 21: Checking Front Planetary Ring Gear Operation
    G04015221Courtesy of SUZUKI OF AMERICA CORP.
  42. Install separator plates "S", friction plates "F" and retaining plates "R" in the following order.

    R --> F --> S --> F --> S --> F --> S --> F --> S --> F --> R

  43. Install snap ring, using flat end rod or the like.
    NOTE: Make sure that opening end of ring is not aligned with protrusion of transaxle case.
    Fig 22: Checking Front Planetary Ring Gear Operation
    G04015222Courtesy of SUZUKI OF AMERICA CORP.
  44. Measure 1st / reverse brake piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm2 , 57 - 113 psi) through oil hole (1) by using special tools. If measured piston stroke exceeds specified value, check for an important installation.

    Special tool 

    (A): 09900-20607 

    (B): 09900-20701 

    1st / reverse brake piston stroke 

    Standard: 1.35 - 2.15 mm (0.053 - 0.085 in.) 

    Fig 23: Measuring 1St / Reverse Brake Piston Stroke
    G04015223Courtesy of SUZUKI OF AMERICA CORP.
  45. Apply petroleum jelly to front planetary carrier rear thrust bearing race (1).
  46. Place front planetary carrier rear thrust bearing race (1) onto planetary front gear (2).
  47. Install planetary front gear (2) to front planetary ring gear (3).
    Fig 24: Installing Planetary Front Gear To Front Planetary Ring Gear
    G04015224Courtesy of SUZUKI OF AMERICA CORP.
  48. Apply petroleum jelly to input shaft front thrust bearing (1) and rear planetary ring gear rear thrust bearing (2).
  49. Install input shaft front thrust bearing (1), planetary sun gear (3), and rear planetary ring gear rear thrust bearing (2) to forward and direct clutch assembly (4).
    Fig 25: Installing Input Shaft Front Thrust Bearing, Planetary Sun Gear, And Rear Planetary Ring Gear Rear Thrust Bearing
    G04015225Courtesy of SUZUKI OF AMERICA CORP.
  50. Apply petroleum jelly to rear planetary ring gear rear thrust bearing race and front planetary carrier rear thrust bearing.
  51. Install rear planetary ring gear rear thrust bearing race (1), rear planetary ring gear (2) and front planetary carrier rear thrust bearing (3) to planetary sun gear (4).
    NOTE: Make sure that tube of rear planetary ring gear rear thrust bearing race fit into notch of rear planetary ring gear.
    Fig 26: Installing Rear Planetary Ring Gear Rear Thrust Bearing Race
    G04015226Courtesy of SUZUKI OF AMERICA CORP.
  52. Install forward and direct clutch assembly (1).
  53. Apply petroleum jelly to input shaft thrust bearing front race (2) and input shaft rear thrust bearing (3).
  54. Place input shaft rear thrust bearing front race (2) and input shaft rear thrust bearing (3) to forward and direct clutch assembly (1).
    Fig 27: Placing Input Shaft Rear Thrust Bearing Front Race And Input Shaft Rear Thrust Bearing
    G04015227Courtesy of SUZUKI OF AMERICA CORP.
  55. Apply A/T fluid to 4 new gaskets (1).
  56. Install 4 new gaskets (1) to transaxle case.
  57. Apply A/T fluid to transaxle lubrication tubes (2).
  58. Install tube clamp (3) and tighten the Torx® bolt to specified torque.

    Tightening torque 

    Tube clamp Torx® bolt (a): 5.5 N.m (0.55 kg-m, 3.98 lb-ft) 

    Fig 28: Installing Tube Clamp
    G04015228Courtesy of SUZUKI OF AMERICA CORP.
  59. Apply petroleum jelly to input shaft rear thrust bearing rear race (1).
  60. Place input shaft rear thrust bearing rear race (1) to transaxle rear cover (2).
    Fig 29: Placing Input Shaft Rear Thrust Bearing Rear Race To Transaxle Rear Cover
    G04015229Courtesy of SUZUKI OF AMERICA CORP.
  61. Apply sealant to mating surface of transaxle case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter.

    "A": Sealant 99000-31230 

    Fig 30: Applying Sealant To Mating Surface Of Transaxle Case
    G04015230Courtesy of SUZUKI OF AMERICA CORP.
  62. Install transaxle rear cover to transaxle case by a tightening bolts to specified torque.
    BOLT SPECIFICATION

    Bolt Size Length (mm) Pieces
    A M6 16 2
    B M8 25 2
    C M8 45 4
    D M8 48 3
    NOTE: Make sure to use new transaxle rear cover bolts A, B and D.

    Tightening torque 

    Transaxle rear cover bolts (a): 10 N.m (1.0 kg-m, 7.5 lb-ft) 

    Transaxle rear cover bolts (b): 24 N.m (2.4 kg-m, 17.5 lb-ft) 

    Fig 31: Tightening Transaxle Rear Cover Bolts
    G04015231Courtesy of SUZUKI OF AMERICA CORP.
  63. Apply A/T fluid to inner surface of new countershaft front bearing (1).
  64. Install new countershaft front bearing (1) to transaxle housing, using special tool.

    Special tool 

    (A): 09913-75510 

    Fig 32: Installing Countershaft Front Bearing To Transaxle Housing
    G04015232Courtesy of SUZUKI OF AMERICA CORP.
  65. Apply A/T fluid to new oil seal ring (1) and install oil seal ring (1) to transaxle housing.
    NOTE: Do not spread oil seal ring ends excessively.
  66. Apply A/T fluid to transaxle rubrication tube (2).
  67. Install tube clamp (3) and tighten the bolt to specified torque.

    Tightening torque 

    Transaxle lubrication tube bolt (a): 10 N.m (1.0 kg-m, 7.5 lb-ft) 

  68. Install oil reservoir RH plate and tighten 3 bolts to specified torque.

    Tightening torque 

    Oil reservoir RH plate bolt (b): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

    Fig 33: Installing Oil Reservoir RH Plate
    G04015233Courtesy of SUZUKI OF AMERICA CORP.
  69. Install oil reservoir LH plate (1) and tighten 2 bolts to specified torque.

    Tightening torque 

    Oil reservoir LH plate bolts (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

    Fig 34: Installing Oil Reservoir LH Plate
    G04015234Courtesy of SUZUKI OF AMERICA CORP.
  70. Install oil strainer assembly (1) and tighten the bolt to specified torque.

    Tightening torque 

    Oil strainer bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

  71. Install differential gear assembly.
    Fig 35: Installing Oil Strainer Assembly
    G04015235Courtesy of SUZUKI OF AMERICA CORP.
  72. Apply sealant to mating surface of transaxle case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter.

    "A": Sealant 99000-31230 

    Fig 36: Applying Sealant To Mating Surface Of Transaxle Case
    G04015236Courtesy of SUZUKI OF AMERICA CORP.
  73. Install transaxle housing to transaxle case by 15 tightening bolts to specified torque.
    BOLT SPECIFICATION

    Bolt Size Length (mm) Pieces
    A M8 30 9
    B M8 30 4
    C M8 35 2
    D M8 45 1
    E M8 Torx® T40 30 1

    Tightening torque 

    Transaxle case bolt: 29 N.m (2.9 kg-m, 20.98 lb-ft) 

    NOTE: Make sure to use new transaxle housing bolts B and C.
    Fig 37: Tightening Transaxle Case Bolt
    G04015237Courtesy of SUZUKI OF AMERICA CORP.
  74. Install one-way No. 1 clutch assembly (1) into oil pump assembly (2).
    Fig 38: Installing One-Way No. 1 Clutch Assembly Into Oil Pump Assembly
    G04015238Courtesy of SUZUKI OF AMERICA CORP.
  75. Check for correct installation of each component parts as follows.

    Measure the distance "a" by using vernier (1) and straight edge (2). If distance is out of specification, remove one-way No. 1 clutch assembly (3) and install them properly.

    Distance between upper edge of one-way No. 1 clutch to oil pump plate 

    "a": 51.1 - 51.7 mm (2.012 - 2.035 in.) 

    Fig 39: Measuring Distance "A" By Using Vernier And Straight Edge
    G04015239Courtesy of SUZUKI OF AMERICA CORP.
  76. Apply A/T fluid to O-ring and install oil pump assembly (1) by 8 tightening bolts to specified torque.
    NOTE: Do not twist or deviate O-ring during installation.

    Tightening torque 

    Oil pump body bolt: 25 N.m (2.5 kg-m, 18.08 lb-ft) 

    Fig 40: Tightening Oil Pump Body Bolt
    G04015240Courtesy of SUZUKI OF AMERICA CORP.
  77. Measure end play of input shaft (1), using special tool. If end play is out of specification, replace input shaft rear thrust bearing front race in the following so as end play to be in standard value.

    Special tool 

    (A): 09900-20607 

    (B): 09900-20701 

    End play of input shaft 

    Standard: 0.37 - 0.90 mm (0.0034 - 0.035 in.) 

    Available input shaft rear thrust bearing front race thickness 

    0.81 mm (0.031 in.), 1.15 mm (0.045 in.) 

    Fig 41: Measuring End Play Of Input Shaft
    G04015241Courtesy of SUZUKI OF AMERICA CORP.
  78. Apply A/T fluid to new gaskets (1) and install gaskets (1) to transaxle case.
    Fig 42: Installing Gaskets To Transaxle Case
    G04015242Courtesy of SUZUKI OF AMERICA CORP.
  79. While holding valve body assembly, connect manual valve connecting rod (1) to manual shift shaft (2).
  80. Install valve body assembly (3) by 9 tightening bolts to specified torque.

    Tightening torque 

    Valve body bolt: 10 N.m (1.0 kg-m, 7.5 lb-ft) 

    BOLT SPECIFICATION

    Bolt Length (mm) Pieces
    A 16 2
    B 50 4
    C 55 3
    Fig 43: Tightening Valve Body Bolt
    G04015243Courtesy of SUZUKI OF AMERICA CORP.
  81. Apply A/T fluid to new O-ring and install O-ring to solenoid harness (1).
  82. Install solenoid harness (1) into transaxle case.
    NOTE: Do not twist or deviate O-ring during installation.
  83. Connect solenoid connectors by identifying wire color.

    Solenoid coupler: Wire color

    Pressure control solenoid valve (1): Blue + Brawn

    Shift solenoid valve-A (No. 1) (2): White

    Shift solenoid valve-B (No. 2) (3): Black

    TCC solenoid valve (4): Yellow

  84. Clamp solenoid harness.
    Fig 44: Connecting Solenoid Connectors
    G04015244Courtesy of SUZUKI OF AMERICA CORP.
  85. Apply sealant to mating surface of transaxle case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter.

    "A": Sealant 99000-31230 

    Fig 45: Applying Sealant To Mating Surface Of Transaxle Case
    G04015245Courtesy of SUZUKI OF AMERICA CORP.
  86. Install transaxle side cover (1) by tightening new Torx® bolts to specified torque.

    Tightening torque 

    Transaxle side cover bolts (a): 13 N.m (1.3 kg-m, 9.5 lb-ft) 

    Fig 46: Installing Transaxle Side Cover
    G04015246Courtesy of SUZUKI OF AMERICA CORP.
  87. Apply A/T fluid to transmission fluid temperature sensor (1), output shaft speed sensor (2), input shaft speed sensor (3), vehicle speed sensor (4) and fluid filler tube (5).
  88. Install input shaft speed sensor and output shaft speed sensor (with new O-rings installed) by tightening bolts to specified torque.

    Tightening torque 

    Input shaft speed sensor bolt (a): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

    Output shaft speed sensor bolt (b): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

  89. Install fluid filler tube (with new O-ring installed).
  90. Install transmission fluid temperature sensor (with new O-ring installed) to specified torque.

    Tightening torque 

    Transmission fluid temperature sensor (d): 10 N.m (1.0 kg-m, 7.2 lb-ft) 

  91. Install vehicle speed sensor (with new O-ring installed) by tightening bolt to specified torque.

    Tightening torque 

    Vehicle speed sensor bolt (e): 10 N.m (1.0 kg-m, 7.2 lb-ft) 

    Fig 47: Installing Vehicle Speed Sensor
    G04015247Courtesy of SUZUKI OF AMERICA CORP.
  92. Install transmission range sensor assembly.
    1. Install transmission range sensor plate (1) to groove of solenoid harness.
    2. Install transmission range sensor (2) to manual valve lever shaft (3).
    3. Place lock washer (4).
    4. Insert transmission range sensor bolts.
    5. Tighten transmission range sensor lock nut (5) to specified torque and then bend claws lock washer.

      Tightening torque 

      Transmission range sensor lock nut (a): 7.0 N.m (0.7 kg-m, 5.0 lb-ft) 

    6. Install manual shift lever (6), washer (7) and tighten nut (8) to specified torque.

      Tightening torque 

      Manual select lever nut (b): 16 N.m (1.6 kg-m, 11.5 lb-ft) 

    7. Adjust transmission range sensor.
    8. Tighten transmission range sensor bolt and nut to specified torque.

    Tightening torque 

    Transmission range sensor bolt (c): 25 N.m (2.5 kg-m, 18.0 lb-ft) 

    Transmission range sensor nut (d): 7.5 N.m (0.75 kg-m, 5.5 lb-ft) 

    Fig 48: Installing Manual Shift Lever, Washer And Nut
    G04015248Courtesy of SUZUKI OF AMERICA CORP.
  93. Install torque converter (1) to input shaft.
    1. Install torque converter (1), using care not to damage oil seal of oil pump.
    2. After installing torque converter (1), check that distance "a" is within specification.

      Distance between torque converter and mating surface of transaxle housing (3) 

      "a": 21.5 mm (0.846 in.) or more 

    3. Check torque converter (1) for smooth rotation.
    CAUTION:
    • Before installing converter, make sure that its pump hub portion is free from nicks, burrs or damage which may cause oil seal to leak.
    • Be very careful not to drop converter on oil pump gear. Damage in gear, should it occur, may cause a critical trouble.
Fig 49: Checking Torque Converter Operation
G04015249Courtesy of SUZUKI OF AMERICA CORP.
scientia non olet · About LEMON Manuals