Suzuki Grand Vitara JB416 / JB420. Manual - part 247

5A-122 Automatic Transmission/Transaxle: 

• When installing brake discs, brake plates and clutch 

backing plate, refer to “Center Support Components”.

• Install clutch backing plate (1) with its flat side facing 

brake disc.

• After installing each retaining backing plate ring, 

measure movement of brake piston again.
If it is not within standard range, it is possible that ring 
is not installed properly. Then disassemble and 
reassemble again.

Standard movement of second coast brake piston 
and second brake piston
Second coast brake piston: 1.00 – 1.20 mm (0.039 
– 0.047 in.)
Second brake piston: 1.01 – 2.25 mm (0.040 – 
0.089 in.)

Center Support Inspection

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• 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.

 

• Measure inside diameter of center support hub 

bushing. If inside diameter exceeds limit, replace 
center support.

Center support bushing inside diameter standard
36.386 – 36.411 mm (1.4325 – 1.4335 in.)

• Measure inside diameter of planetary sun gear 

bushing. If inside diameter exceeds limit, replace 
planetary sun gear.

Planetary sun gear bushing inside diameter 
standard
21.501 – 21.527 mm (0.8465 – 0.8475 in.)

• Measure free length of piston return spring.

Standard free length of second coast brake piston 
return spring
16.84 mm (0.663 in.)

Standard free length of second brake piston 
return spring
15.82 mm (0.623 in.)

2. Step

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Automatic Transmission/Transaxle:  5A-123

Planetary Gears and Output Shaft Components

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9

4

5

3

2

2

11

10

13

2

12

18

14

16

15

16

14

2

17

1

10

6

18

FLD

8

FLD

7

FLD

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1. Inner shaft

6. Front planetary gear

11. Front planetary ring gear

16. Bearing race

2. Retaining ring

7. Reverse brake plate

12. Rear planetary gear

17. Output shaft assembly

3. Reverse brake reaction plate

8. Reverse brake disc

13. Planetary sun gear

18. Seal ring

4. One-way clutch

9. Reverse brake backing plate

14. Bearing

: Apply A/T fluid.

5. One-way clutch thrust washer

10. Thrust washer

15. Rear planetary ring gear

5A-124 Automatic Transmission/Transaxle: 

Planetary Gears and Output Shaft Disassembly 
and Assembly

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Disassembly

1) Remove front planetary gear assembly (1) from 

output shaft assembly (2).

2) Remove rear planetary thrust washer (1), reverse 

brake backing plate (2), reverse brake disc (3) and 
reverse brake plate (4) from front planetary gear 
assembly.

3) Remove reverse brake reaction plate (2) from front 

planetary gear (1).

4) After removing retaining ring (1), remove one-way 

clutch (2) and one-way clutch rear thrust washer (3).

5) After removing retaining ring (1), remove front 

planetary ring gear (2), thrust bearing and bearing 
race.

6) Remove thrust washer (1), rear planetary gear (2) 

and rear planetary sun gear (3).

7) After removing retaining ring (2) from inner shaft (1), 

remove rear planetary ring gear (3) and thrust 
bearing assembly.

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4. Front planetary gear

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Automatic Transmission/Transaxle:  5A-125

Assembly
Assemble components by reversing disassembly 
procedure and noting the following points.
• Refer to “Planetary Gears and Output Shaft 

Components” when installing each component.

• Check seal ring for damage before installation and 

replace if damaged.

• Install planetary sun gear as shown in the figure.

NOTE
A is longer than B.

 

• Fit retaining rings into groove securely.
• Install one-way clutch as shown in the figure.

• Install reverse brake reaction plate (2) to front 

planetary gear (1).
With reverse brake reaction plate (2) fixed stationary, 
turn front planetary gear (1) clockwise to check that it 
locks and then counterclockwise to check that it turns 
smoothly.

Planetary Gears and Output Shaft Inspection

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• 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.

 

• Measure inside diameter of output shaft bushing. If 

inside diameter exceeds limit, replace output shaft.

Output shaft bushing inside diameter standard
18.001 – 18.026 mm (0.7087 – 0.7097 in.)

1. Front planetary gear side

[A]: Rotates
[B]: Locks

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