Suzuki Grand Vitara JB416 / JB420. Manual - part 244

5A-110 Automatic Transmission/Transaxle: 

Overdrive (Case Side) Disassembly and 
Assembly

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Disassembly

1) Remove retaining ring (1), brake backing plate (2), 

brake disc (3) and brake plate (4) in that order. Then 
remove planetary ring gear, thrust bearing race and 
thrust bearing.

2) Remove retaining ring and piston return spring using 

special tool and press (1).

Special tool
(A):  09926–96510

CAUTION

!

 

Be careful when applying pressure, for 
overpressure will cause plate section of 
piston return spring to deform.

 

3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm

2

, 

57 – 113 psi) to oil hole (1) in O/D case (2) and 
remove brake piston.

4) Remove brake piston inner ring and brake piston 

outer ring from brake piston.

5) Unsnap seal ring (1).
6) Remove 2 seal rings (1).

NOTE
Be careful not to open seal ring more than 
necessary.

 

1

2

3

4

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1

(A)

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1

2

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Automatic Transmission/Transaxle:  5A-111

Assembly
Install each component by reversing removal procedure 
and noting the following points.
• When installing rear seal ring, use care not to open it 

too wide.

• Apply A/T fluid to O-ring, disc, etc. before installing 

them.

• Opening of retaining brake front ring (2) and 

projection (1) of O/D case should be matched.

• When installing each component, refer to “Overdrive 

(Case Side) Components”.

• Measure clearance between retaining ring (1) and 

brake backing plate (2) with thickness gauge.
If the clearance is out of specification, select another 
plate with suitable thickness from the list below and 
replace it.

Standard clearance between retaining ring and 
brake backing plate
0.40 – 1.38 mm (0.016 – 0.054 in.)

Overdrive (Case Side) Inspection

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• Measure free length of piston return spring.

Standard free length of O/D brake piston return 
spring
15.10 mm (0.594 in.)

• Check that sliding surface of discs and plate are not 

worn or burnt. If necessary, replace them.

NOTE

• If disc lining is exfoliated, discolored or 

worn hardly, replace all discs.

• If only a part of printed numbers is 

corroded, replace all discs.

• Before assembling new discs, soak them 

in A/T fluid for at least 15 minutes.

 

Thickness

1.95 – 2.05 mm (0.077 – 0.081 in.)
2.25 – 2.35 mm (0.089 – 0.093 in.)

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5A-112 Automatic Transmission/Transaxle: 

Forward Clutch Components

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Forward Clutch Disassembly and Assembly

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Disassembly

1) After removing retaining ring (1), remove direct 

clutch hub (2) and forward clutch hub (3).

2) Remove bearing race (1) and thrust bearing (2).

3) Remove retaining ring (1) and then remove all clutch 

discs.

1

2

3

4

5

5

5

6

7

8

9

10

11

FLD

FLD

FLD

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1. Input shaft

5. Retaining ring

9. Clutch disc

: Apply A/T fluid.

2. Piston

6. Bearing race

10. Froward clutch hub

3. Return spring

7. Bearing

11. Direct clutch hub

4. O-ring

8. Clutch plate

: Do not reuse.

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Automatic Transmission/Transaxle:  5A-113

4) Using special tool and hydraulic press, compress 

forward clutch piston return spring and remove 
retaining return spring.

Special tool
(A):  09926–98310 

CAUTION

!

 

Be careful when applying pressure, for 
overpressure will cause plate section of 
piston return spring to deform.

 

5) Remove forward clutch piston return spring.

6) Install forward clutch to O/D case (1). Blow low 

pressure air into fluid hole (2) at the right of cut in O/
D case to remove forward clutch piston (3).

Assembly

1) Apply A/T fluid to forward input shaft O-rings, install 

forward clutch piston and piston return spring (2) to 
forward input shaft and then install return spring ring 
with special tool and hydraulic press.

Special tool
(A):  09926–98310 

NOTE

• When installing return spring (2), be 

careful so that return spring will not fall or 
tilt.

• Do not align opening in retaining ring (1) 

with lug of forward clutch piston return 
spring at its retainer section.

 

CAUTION

!

 

Be careful when applying pressure, for 
overpressure will cause plate section of 
piston return spring to deform.

 

2) Install clutch discs and plates and then install 

retaining clutch ring.

NOTE

• Refer to “Forward Clutch Components” 

when installing each component.

• Do not match opening in retaining clutch 

ring and dent in forward clutch input shaft.

 

3) Install bearing races (1) and thrust bearing (2).

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