Suzuki Grand Vitara JB416 / JB420. Manual - part 249

5A-130 Automatic Transmission/Transaxle: 

18) When clutch disc and plate have been replaced, 

check height difference between forward clutch input 
shaft and transmission case (1) by measuring as 
shown in the figure.

NOTE
If measured value is less than standard 
value, remove forward clutch assembly and 
install it again.

 

Standard height difference between forward 
clutch input shaft and transmission case
“a”: About 2.0 mm (0.079 in.)

19) Apply grease to thrust bearing (1) and bearing race 

(2), and then install them to forward clutch input 
shaft.

20) Install O/D case by aligning cutout in O/D case (1) 

and that in transmission case.

NOTE
Use care not to drop thrust rear race installed 
to O/D case.

 

21) Apply grease to thrust washers (1) and install them 

to O/D planetary gear (2) and planetary ring gear (3), 
and then install O/D input shaft assembly to O/D 
case.

NOTE

• Fit claws of thrust washer into holes 

securely.

• Use care not to drop thrust washer 

installed to O/D planetary gear.

 

22) When clutch disc or plate has been replaced, check 

height difference between O/D case (1) and O/D 
clutch cylinder (2) by measuring it as shown in the 
figure.

NOTE
Measure at the highest point along inner 
circumference of O/D clutch cylinder.

 

Standard height difference between O/D case 
and O/D clutch cylinder
“a”: About 3.5 mm (0.138 in.)

2. Forward clutch

2. Cutout in automatic transmission

2

1

“a”

I5JB0A510135-01

2

1

I5JB0A510136-01

1

2

I5JB0A510137-02

I5JB0A510138-01

I5JB0A510161-01

Automatic Transmission/Transaxle:  5A-131

23) Apply A/T fluid to new housing O-ring and install it to 

O/D case. Then install converter housing (1) and 
tighten housing bolt to specified torque.

Tightening torque
Torque converter housing bolt (a):  35 N·m (3.5 
kgf-m, 25.5 lb-ft)
Torque converter housing bolt (b):  58 N·m (5.8 
kgf-m, 42.0 lb-ft)

24) Apply grease to bearing race (1) and thrust bearing 

(2) and install them to O/D clutch cylinder.

25) Apply A/T fluid to new oil pump cover O-ring and 

install it to oil pump assembly. Then install oil pump 
assembly aligning bolt holes in O/D case with those 
in transmission case oil pump assembly. Apply seal 
packing to oil pump assembly bolts and tighten them 
by certain amount of torque at each time one after 
another till specified torque is attained.

Tightening torque
Oil pump bolt (a):  22 N·m (2.2 kgf-m, 16.0 lb-ft)

26) Apply 2 – 4 kg/cm

2

 air pressure into fluid holes in the 

figure as numbered and check operation sound of 
each part.

27) Take down transmission from stand and install new 

gasket and cover plate (1).

28) Measure clearance in shaft direction by applying dial 

gauge (1) to output shaft as shown in the figure.

Standard clearance in shaft direction
0.3 – 0.9 mm (0.012 – 0.035 in.)

I5JB0A510162-01

1

2

I5JB0A510139-01

IYSQ01510257-01

1. O/D clutch

5. Second coast brake

2. O/D brake

6. Second brake

3. Forward clutch

7. Reverse brake

4. Direct clutch

IYSQ01510258-01

1

I5JB0A510089-01

IYSQ01510259-01

5A-132 Automatic Transmission/Transaxle: 

29) Check that inner shaft runs smoothly.
30) Apply grease to lip of new oil lip seal and drive in oil 

lip seal with special tool till it contacts transmission 
case.

Special tool
(A):  09923–46020 

31) Install a new spacer (1) to manual shift lever (2).
32) Install manual shift shaft (3) to transmission case 

through manual shift lever.

33) Drive in manual shift lever pin (1) by using hammer.

34) Align hole in sleeve cover with dent in manual shift 

lever and caulk securely with pin punch (1). Then 
check that manual shift shaft turns smoothly.

35) Install parking lock pawl (2), parking pawl pin (1) and 

parking pawl spring (3).

36) Connect parking lock rod (2) to manual shift lever (1) 

as shown in the figure.

37) Install parking lock pawl bracket (1).

Tighten parking pawl bracket bolts (2) to specified 
torque.

Tightening torque
Parking pawl bracket bolt (a):  7.4 N·m (0.74 kgf-
m, 5.5 lb-ft)

IYSQ01510261-01

2

1

3

I4JA01512266-01

1

I4JA01512267-01

1

I4JA01512268-01

2

1

3

I4JA01512269-01

1

2

I4JA01512270-01

1

2, (a)

I4JA01512271-01

Automatic Transmission/Transaxle:  5A-133

38) Apply A/T fluid to new O-ring and spring and install 

them to accumulator piston and install accumulator 
piston to transmission case.

Accumulator spring specification

39) After confirming that accumulator piston is pushed all 

the way down, match pin of manual shift lever with 
groove in manual valve.

40) Fix valve body (1) by using bolts with each nominal 

length as indicated in the figure and tightening to 
specified torque.

Tightening torque
Valve body bolt:  10 N·m (1.0 kgf-m, 7.5 lb-ft)

Valve body bolt nominal length
“a”: 28 mm (1.10 in.)
“b”: 30 mm (1.18 in.)
“c”: 36 mm (1.42 in.)
“d”: 45 mm (1.77 in.)

41) Install O/D brake applying tube (1).

42) Lubricate new O-ring with A/T fluid and attach it to 

grommet of solenoid wire harness. Then connect 
solenoid wire harness to transmission case and fix it 
with solenoid wire harness clamp. Connect each 
connector to solenoid. And install new gasket and 
brake applying cover.

Tightening torque
Transmission wire connector bolt (a):  16 N·m (
1.6 kgf-m, 11.5 lb-ft)

Accumulator 

piston

Accumulator spring

Spring free 

length “a”

Color

Forward clutch

75.03

White + Blue

Direct clutch

57.74

White + Purple

Second brake

56.16

Purple

1. Forward clutch accumulator piston
2. Direct clutch accumulator piston
3. Second brake accumulator piston
4. Accumulator spring

4

3

1

2

“a”

I5JB0A510140-02

IYSQ01510269-01

“a”

“a”

“a”

1

“b”

“b”

“c”

“c”

“c”

“d”

“d”

“d”

“d”

I5JB0A510141-01

1

I5JB0A510143-02

(a)

I5JB0A510142-01