Suzuki Grand Vitara JB416 / JB420. Manual - part 217
5A-2 Automatic Transmission/Transaxle:
• Select a clean place free from dust and dirt for
overhauling.
• Place a rubber mat on the work bench to protect parts
from damage.
• Work gloves or shop cloth should not be used. (Use
nylon cloth or paper towel.)
• When separating the case joint, do not pry with a
screwdriver or such but tap with a plastic hammer
lightly.
• Wash the disassembled parts in ATF (Automatic
Transmission Fluid) or kerosene (using care not to
allow ATF or kerosene to get on your face, etc.) and
confirm that each fluid passage is not clogged by
blowing air into it. But use ATF to wash the disc, resin
washers and rubber parts.
• Replace each gasket, oil seal and O-ring with a new
one.
• Apply ATF to sliding or rotating parts before
reassembly.
• A new disc should be soaked in ATF at least 2 hours
before use.
Part Inspection and Correction Table
Part
Inspect for
Correction
Casted part, machined part Small flaw, burr
Remove with oil stone.
Deep or grooved flaw
Replace part.
Clogged fluid passage
Clean with air or wire.
Flaw on installing surface, residual gasket
Remove with oil stone or replace part.
Crack
Replace part.
Bearing
Unsmooth rotation
Replace.
Streak, pitting, flaw, crack
Replace.
Bushing, thrust washer
Flaw, burr, wear, burning
Replace.
Oil seal, gasket
Flawed or hardened seal ring
Replace.
Worn seal ring on its periphery or side
Replace.
Piston seal ring, oil seal, gasket, etc.
Replace.
Gear
Flaw, burr
Replace.
Worn gear tooth
Replace.
Splined part
Burr, flaw, torsion
Correct with oil stone or replace.
Snap ring
Wear, flaw, distortion
Replace.
No interference
Replace.
Thread
Burr
Replace.
Damage
Replace.
Spring
Settling, sign of burning
Replace.
Clutch disc, brake disc
Wear, burning, distortion, damaged claw
Replace.
Clutch plate, brake plate
Wear, burning, distortion, damaged claw
Replace.
Sealing surface (where lip
contacts)
Flaw, rough surface, stepped wear, foreign
material
Replace.