Transmission Assembly Disassembly

CAUTION: Do not disassemble parts behind Drum Support. Refer to [CROSS-SECTIONAL VIEW ].

Drain A/T fluid through drain plug.
Remove torque converter by holding it firmly and turning while pulling straight out.

Fig 1: Removing Torque Converter
Courtesy of SUZUKI OF AMERICA CORP.
Check torque converter one-way clutch using a check tool as shown.

Fig 2: Checking Torque Converter One-Way Clutch Using Check Tool
Courtesy of SUZUKI OF AMERICA CORP.
1. Insert a check tool into the groove of bearing support built into one-way clutch outer race.
2. While holding bearing support with a check tool, rotate one-way clutch spline using suitable tool.
3. Make sure that inner race rotates clockwise only. If not, replace torque converter assembly.
Remove bolts and converter housing from transmission case.

Fig 3: Locating Converter Housing Bolts
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not scratch converter housing.
- Self-sealing bolt (A)
Remove O-ring from input clutch assembly.

Fig 4: Identifying Input Clutch Assembly With O-Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pump assembly to transmission case bolts.

Fig 5: Locating Transmission Case Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the oil pump assembly evenly from the transmission case using Tools.

Fig 6: Removing Oil Pump Assembly
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: ST25850000 (J-25721-A)
CAUTION:
- Fully tighten the sliding hammer screws.
- Make sure that bearing race is installed to the oil pump assembly edge surface.
Remove O-ring from oil pump assembly.

Fig 7: Removing O-Ring From Oil Pump Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing race from oil pump assembly.

Fig 8: Identifying Bearing Race
Courtesy of SUZUKI OF AMERICA CORP.
Remove needle bearing from front sun gear.

Fig 9: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove front sun gear assembly from front carrier assembly.

Fig 10: Removing Front Sun Gear Assembly From Front Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Remove front sun gear by rotating it left and right.
Remove seal rings from input clutch assembly.

Fig 11: Identifying Input Clutch Assembly Seal Rings
Courtesy of SUZUKI OF AMERICA CORP.
Remove front carrier assembly (with input clutch assembly and rear internal gear) from rear carrier assembly.

Fig 12: Identifying Front Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not remove it with needle bearing.
Loosen lock nut and remove band servo anchor end pin from transmission case.

Fig 13: Identifying Transmission Case Lock Nut
Courtesy of SUZUKI OF AMERICA CORP.
Remove brake band from transmission case.

Fig 14: Identifying Brake Band
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- To prevent brake linings from cracking or peeling, do not stretch the flexible band unnecessarily. When removing the brake band, always secure it with a clip as shown.
  
  Fig 15: Removing Clip
  Courtesy of SUZUKI OF AMERICA CORP.
- Check brake band facing for damage, cracks, wear or burns.
Remove mid carrier assembly and rear carrier assembly as a unit.

Fig 16: Identifying Mid Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove mid carrier assembly from rear carrier assembly.

Fig 17: Removing Mid Carrier Assembly From Rear Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove needle bearing (front side) from mid carrier assembly.

Fig 18: Removing Needle Bearing (Front Side) From Mid Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove needle bearing (rear side) from mid carrier assembly.

Fig 19: Removing Needle Bearing (Rear Side) From Mid Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing race from rear carrier assembly.

Fig 20: Removing Bearing Race From Rear Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove needle bearing from rear carrier assembly.

Fig 21: Removing Needle Bearing From Rear Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove mid sun gear assembly, rear sun gear assembly and high and low reverse clutch hub as a unit.

Fig 22: Identifying Mid Sun Gear Assembly And Rear Sun Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Remove them with bearing race and needle bearing.
Remove high and low reverse clutch assembly from direct clutch assembly.

Fig 23: Identifying High And Low Reverse Clutch Assembly
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Make sure that needle bearing is installed to the high and low reverse clutch assembly edge surface.
Remove needle bearing from drum support.

Fig 24: Identifying Needle Bearing And Drum Support
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch assembly from reverse brake.

Fig 25: Identifying Direct Clutch Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring from A/T assembly harness connector.

Fig 26: Removing Snap Ring From A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.
Push A/T assembly harness connector.

Fig 27: Pushing A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not damage connector.
Remove oil pan and oil pan gasket. Refer to [OIL PAN: REMOVAL AND INSTALLATION ].
Check foreign materials in oil pan to help determine causes of malfunction. If the A/T fluid is very dark, smells burned, or contains foreign particles, the frictional material (clutches, band) may need replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to stick and can inhibit pump pressure.

Fig 28: Identifying Foreign Materials In Oil Pan
Courtesy of SUZUKI OF AMERICA CORP.
- If frictional material is detected, perform A/T fluid cooler cleaning. Refer to [A/T FLUID COOLER CLEANING ].
Remove magnets from oil pan.

Fig 29: Identifying Oil Pan Magnets
Courtesy of SUZUKI OF AMERICA CORP.
Straighten terminal clips (<==) to free terminal cord assembly and A/T fluid temperature sensor 2 harness.

Fig 30: Identifying A/T Fluid Temperature Sensor 2 Connector And Terminal Clip
Courtesy of SUZUKI OF AMERICA CORP.
- <==: Terminal clip (4)
Disconnect A/T fluid temperature sensor 2 connector (A).
CAUTION: Do not damage connector.
Straighten terminal clip to free revolution sensor harness.

Fig 31: Identifying Terminal Clip And Revolution Sensor Harness
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect revolution sensor connector.
CAUTION: Do not damage connector.

Remove bolts (A), (B) and (C) from control valve with TCM.

Fig 32: Identifying Control Valve Bolts

Courtesy of SUZUKI OF AMERICA CORP.

BOLT LENGTH SPECIFICATION

Bolt symbol	Length mm (in)	Number of bolts
A	42 (1.65)	5
B	55 (2.17)	6
C	40 (1.57)	1

Remove control valve with TCM from transmission case.

Fig 33: Removing Control Valve With TCM From Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: When removing, be careful with the manual valve notch and manual plate height. Remove it vertically.
Remove A/T fluid temperature sensor 2 with bracket from control valve with TCM.

Fig 34: Identifying A/T Fluid Temperature Sensor 2 With Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Remove bracket from A/T fluid temperature sensor 2.

Fig 35: Identifying Bracket And A/T Fluid Temperature Sensor 2
Courtesy of SUZUKI OF AMERICA CORP.
Remove O-ring from A/T assembly harness connector.

Fig 36: Identifying O-Ring And A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect TCM connectors.

Fig 37: Identifying TCM Connectors
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not damage connectors.
Remove A/T assembly harness connector from control valve with TCM using suitable tool.

Fig 38: Removing A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect TCM connector and park/neutral position switch connector.

Fig 39: Identifying TCM Connector And Park/Neutral Position Switch Connector
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not damage connectors.
Remove rear extension assembly (2WD models) or adapter case assembly (4WD models) according to the following procedures.
1. 2WD models
  
  Fig 40: Identifying Rear Extension Assembly Bracket Bolts
  Courtesy of SUZUKI OF AMERICA CORP.
  1. Remove tightening bolts for rear extension assembly and transmission case.
    - Bracket (1)
    - Bracket (2)
    - Self-sealing bolts (3)
    - Bolt (A)
  2. Tap rear extension assembly with soft hammer.
    
    Fig 41: Tapping Rear Extension Assembly With Soft Hammer
    Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove rear extension assembly (with needle bearing) from transmission case.
    
    Fig 42: Removing Rear Extension Assembly
    Courtesy of SUZUKI OF AMERICA CORP.
2. 4WD models
  
  Fig 43: Locating Transmission Housing Bolts (4WD Models)
  Courtesy of SUZUKI OF AMERICA CORP.
  1. Remove adapter case to transmission case bolts and terminal bracket (2).
    - <== Front (1)
    - Self-sealing bolt (3)
  2. Tap adapter case assembly using suitable tool.
    
    Fig 44: Tapping Adapter Case Assembly
    Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove adapter case assembly (with needle bearing) from transmission case.
    
    Fig 45: Removing Adapter Case Assembly
    Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove gasket from transmission case.
    
    Fig 46: Removing Gasket From Transmission Case
    Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing race from output shaft.

Fig 47: Removing Bearing Race From Output Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove output shaft from transmission case by rotating left and right.

Fig 48: Removing Output Shaft From Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove parking gear from output shaft.

Fig 49: Removing Parking Gear From Output Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove seal rings from output shaft.

Fig 50: Identifying Seal Rings
Courtesy of SUZUKI OF AMERICA CORP.
Remove needle bearing from transmission case.

Fig 51: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove revolution sensor from transmission case.

Fig 52: Locating Revolution Sensor
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not subject it to impact by dropping or hitting it.
- Do not disassemble.
- Do not allow metal filings or any foreign material to get on the sensor's front edge magnetic area.
- Do not place in an area affected by magnetism.
Remove reverse brake snap ring using two flat-bladed screwdrivers.

Fig 53: Removing Reverse Brake Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Press out snap ring from the transmission case oil pan side gap using a flat-bladed screwdriver, and remove it using a another screwdriver.
Remove reverse brake retaining plate from transmission case.
- Check facing for burns, cracks or damage. If necessary, replace the plate.
Remove N-spring from transmission case.

Fig 54: Identifying Transmission Case N-Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse brake drive plates, driven plates and dish plate from transmission case.

Fig 55: Removing Reverse Brake Drive Plates, Driven Plates And Dish Plate From Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
- Check facing for burns, cracks or damage. If necessary, replace the plate.
Remove snap ring using suitable tool.

Fig 56: Identifying Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove spring retainer and return spring from transmission case.

Fig 57: Identifying Spring Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove seal rings from drum support.

Fig 58: Identifying Seal Rings
Courtesy of SUZUKI OF AMERICA CORP.
Remove needle bearing from drum support edge surface.

Fig 59: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse brake piston from transmission case using compressed air. Refer to [TRANSMISSION ASSEMBLY DISASSEMBLY ].

Fig 60: Removing Reverse Brake Piston
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Care should be taken not to abruptly blow air. It makes the piston incline, and as a result, it becomes hard to disassemble the pistons.
Remove D-rings from reverse brake piston.

Fig 61: Identifying Reverse Brake Piston D-Rings
Courtesy of SUZUKI OF AMERICA CORP.
Knock out retaining pin using suitable tool.

Fig 62: Identifying Retaining Pin And Manual Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove manual shaft retaining pin using suitable tool.

Fig 63: Removing Manual Shaft Retaining Pin
Courtesy of SUZUKI OF AMERICA CORP.
Remove manual plate (with parking rod) from manual shaft.

Fig 64: Removing Manual Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove parking rod from manual plate.

Fig 65: Removing Parking Rod
Courtesy of SUZUKI OF AMERICA CORP.
Remove manual shaft from transmission case.

Fig 66: Removing Manual Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove manual shaft oil seals using suitable tool.

Fig 67: Removing Manual Shaft Oil Seals
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not scratch transmission case.
Remove detent spring and spacer from transmission case.

Fig 68: Locating Detent Spring And Spacer
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring from transmission case using suitable tool.

Fig 69: Removing Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove servo assembly (with return spring) from transmission case.

Fig 70: Removing Servo Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove return spring from servo assembly.

Fig 71: Removing Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove O-rings from servo assembly.

Fig 72: Removing O-Rings
Courtesy of SUZUKI OF AMERICA CORP.
Remove needle bearing (1) from rear extension (2WD models) or adapter case (4WD models).

Fig 73: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove parking actuator support from rear extension (2WD models) or adapter case (4WD models).

Fig 74: Removing Parking Actuator Support
Courtesy of SUZUKI OF AMERICA CORP.
Remove parking pawl (with return spring) and pawl shaft from rear extension (2WD models) or adapter case (4WD models).

Fig 75: Removing Parking Pawl (With Return Spring) And Pawl Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove return spring (1) from parking pawl (2).

Fig 76: Identifying Return Spring And Parking Pawl
Courtesy of SUZUKI OF AMERICA CORP.
Remove rear oil seal from rear extension (2WD models) or adapter case (4WD models) using suitable tool.

Fig 77: Removing Rear Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not scratch rear extension (2WD models) or adapter case (4WD models).