Automatic Transaxle Unit Disassembly

Reference: AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING 

Reference: AUTOMATIC TRANSAXLE ASSEMBLY COMPONENTS 

Reference: AUTOMATIC TRANSAXLE UNIT ASSEMBLY 

1. Extract torque converter (1).
   CAUTION: Remove torque converter as much straight as possible. Leaning it may cause to damage oil seal lip.
   Fig 1: Removing Torque Converter

   Courtesy of SUZUKI OF AMERICA CORP.
2. Pull out transmission range sensor assembly (1).
   1. Remove nut, washer and manual shift lever (2).
   2. Pry off lock washer (4).
   3. Remove lock nut (3).
   4. Remove lock washer (4).
   5. Remove 2 bolts (5).
      NOTE: Never reuse lock washer after removal.
      Fig 2: Removing Transmission Range Sensor Assembly

      Courtesy of SUZUKI OF AMERICA CORP.
3. Remove fluid level gauge (1), fluid filler tube (2), output shaft speed sensor (3), input shaft speed sensor (4) and vehicle speed sensor (5) (for speedometer).
   NOTE: Never reuse fluid filler tube bolt.
4. Disconnect transmission fluid temperature sensor connector (6) and remove transmission fluid temperature sensor (7).
   Fig 3: Removing Transmission Fluid Temperature Sensor

   Courtesy of SUZUKI OF AMERICA CORP.
5. Remove transaxle side cover (1) by removing bolts.
   Fig 4: Removing Transaxle Side Cover

   Courtesy of SUZUKI OF AMERICA CORP.
6. Remove solenoid harness from clamp.
7. Disconnect pressure control solenoid, shift solenoid-A, shift solenoid-B and TCC solenoid connectors (1, 2, 3, 4).
8. Remove solenoid harness (5) with O-ring.
   Fig 5: Disconnecting Pressure Control Solenoid Connectors

   Courtesy of SUZUKI OF AMERICA CORP.
9. Remove valve body assembly (1) by removing 9 bolts (4), and then disconnect manual valve connecting rod (2) from manual valve lever (3).
   CAUTION: Be careful not to let manual valve fall off when removing valve body assembly.
   Fig 6: Removing Valve Body Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
10. Remove 2 gaskets (1).
    Fig 7: Removing Gaskets

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11. Remove 17 bolts (1) of transaxle housing.
12. Remove 8 bolts (2) of oil pump body.
    Fig 8: Removing Transaxle Housing Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
13. Remove transaxle housing with oil pump (1), using special tool, and then remove oil pump body (2) by hand.

    Special Tool 

    1. 09912-34510 
       Fig 9: Removing Transaxle Housing With Oil Pump

       Courtesy of SUZUKI OF AMERICA CORP.
14. Clean and wipe off gasket sealant on mating surface between transaxle housing and transaxle case.
15. Remove oil reservoir RH plate (1) by removing 3 bolts.
16. Remove transaxle lubrication tube (2) by removing the bolt and prying up both ends of the tube.
    Fig 10: Removing Transaxle Lubrication Tube

    Courtesy of SUZUKI OF AMERICA CORP.
17. Remove countershaft front bearing (1) using bearing puller.
    Fig 11: Removing Countershaft Front Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
18. Remove differential gear assembly (1).
19. Remove one-way No. 1 clutch assembly (2) and one-way No. 1 clutch front thrust washer (3).
20. Remove oil strainer assembly (4) by removing bolt (5).
    Fig 12: Removing Differential Gear Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
21. Loosen 11 bolts of transaxle rear cover.
22. Lightly and uniformly tap two rib sections of transaxle rear cover (1), using plastic hammer.
23. Pull out transaxle rear cover (1) and input shaft rear thrust bearing rear race (2).
    Fig 13: Removing Transaxle Rear Cover And Input Shaft Rear Thrust Bearing Rear Race

    Courtesy of SUZUKI OF AMERICA CORP.
24. Remove 4 gaskets (1) from transaxle case.
25. Remove tube clamp (2) and transaxle lubrication tube (3) prying up both ends of the tube.
    Fig 14: Removing Transaxle Lubrication Tube

    Courtesy of SUZUKI OF AMERICA CORP.
26. Remove forward and direct clutch assembly (1), thrust bearing (2) and bearing front race (3) of input shaft rear side.
    Fig 15: Removing Forward And Direct Clutch Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
27. Remove planetary gear (1) and planetary sun gear (2) with the input shaft front thrust bearing (3) installed.
    Fig 16: Removing Planetary Gear

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28. Remove snap ring (1) using flat end rod or the like.
29. Remove front planetary ring gear and one-way No. 2 clutch (2) with front planetary ring gear rear thrust bearing (3).
30. Remove retaining plates "R", friction plates "F" and separator plates "S" in the following order.

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

    Fig 17: Removing Snap Ring

    Courtesy of SUZUKI OF AMERICA CORP.
31. Remove front thrust bearing (2) and bearing race (1) of front planetary ring gear.
32. Remove retainer ring (3) and 1st / reverse brake piston return spring (4).
    Fig 18: Removing Front Thrust Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
33. Remove 1st / reverse brake piston (1) with O-ring installed while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm² , 57 - 113 psi) through oil hole section (2).
    NOTE: If piston will not pop out, it is recommended to use needle nose pliers for removal.
    Fig 19: Applying Compressed Air Through Oil Hole Section

    Courtesy of SUZUKI OF AMERICA CORP.
34. Remove reduction drive gear (2) by removing retainer ring (1).
    Fig 20: Removing Reduction Drive Gear

    Courtesy of SUZUKI OF AMERICA CORP.
35. Remove oil reservoir LH plate (1).
    Fig 21: Removing Oil Reservoir LH Plate

    Courtesy of SUZUKI OF AMERICA CORP.
36. Remove parking lock pawl bracket and manual detent spring (1).
37. Remove parking lock pawl shaft (2), torsion spring (3) and parking lock pawl (4).
38. Remove parking lock rod (5) and manual shift shaft (6).
    Fig 22: Removing Parking Lock Pawl Shaft

    Courtesy of SUZUKI OF AMERICA CORP.
39. Remove underdrive gear assembly (1) with bearing (2) and bearing race (3).
    Fig 23: Removing Underdrive Gear Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
40. Remove torsion spring (1), spacer (2) and underdrive brake accumulator bracket (3).
    Fig 24: Removing Torsion Spring

    Courtesy of SUZUKI OF AMERICA CORP.
41. Remove underdrive brake accumulator cover (1), piston (2) and spring (3) while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm² , 57 - 113 psi) through oil hole (4).
    Fig 25: Removing Underdrive Brake Accumulator Cover

    Courtesy of SUZUKI OF AMERICA CORP.
42. Remove underdrive brake band anchor bolt (1) with O-ring (2).
    Fig 26: Removing Underdrive Brake Band Anchor Bolt

    Courtesy of SUZUKI OF AMERICA CORP.
43. Remove underdrive clutch assembly (1) with bearing (2) and race (3).
    Fig 27: Removing Underdrive Clutch Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
44. Remove underdrive clutch thrust bearing (1).
45. Remove underdrive brake band (2).
    Fig 28: Removing Underdrive Clutch Thrust Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
46. Remove underdrive brake piston as follows.
    1. Using special tool, compress underdrive brake piston cover (2) and remove snap ring using pliers or the like.
    2. Remove cover (2), piston (3) and spring (4) by applying compressed air (400 - 800 kPa, 4 - 8 kg/cm² , 57 - 113 psi) from oil hole (1).
       Fig 29: Removing Snap Ring

       Courtesy of SUZUKI OF AMERICA CORP.
47. Remove snap ring (1) using flat end rod or the like.
48. Remove one-way No. 3 clutch (2).
    Fig 30: Removing One-Way No. 3 Clutch

    Courtesy of SUZUKI OF AMERICA CORP.
49. Remove 2 oil seal rings (1).
    Fig 31: Removing Oil Seal Rings

    Courtesy of SUZUKI OF AMERICA CORP.
50. Remove differential side oil seal (1) using special tools.

    Special Tool 

    1. 09913-75821 
    2. 09924-84510-005 
       Fig 32: Removing Differential Side Oil Seal

       Courtesy of SUZUKI OF AMERICA CORP.
51. Remove manual shift shaft oil seal (1) using flat end rod or the like.
    Fig 33: Removing Manual Shift Shaft Oil Seal

    Courtesy of SUZUKI OF AMERICA CORP.