Suzuki Grand Vitara JB627. Manual - part 204

5-1 Precautions: 

Transmission / Transaxle

Precautions

Precautions

Precautions for Transmission / Transaxle

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Air Bag Warning
Refer to “Air Bag Warning in Section 00”.

Fastener Caution
Refer to “Fastener Caution in Section 00”.

Precautions in Diagnosing Trouble (for A/T)
Refer to “Precautions in Diagnosing Trouble in Section 5A”.

Precautions for Disassembly and Reassembly (for A/T)
Refer to “Precautions for Disassembly and Reassembly in Section 5A”.

Automatic Transmission/Transaxle:  5A-1

Transmission / Transaxle

Automatic Transmission/Transaxle

Precautions

Precautions in Diagnosing Trouble

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• Do not disconnect couplers from TCM, battery cable 

from battery, TCM ground wire harness from engine or 
main fuse before checking the diagnostic information 
(DTC, freeze frame data, etc.) stored in TCM memory. 
Such disconnection will clear memorized information 
in TCM memory.

• Diagnostic information stored in TCM memory can be 

cleared as well as checked by using SUZUKI scan 
tool or OBD generic scan tool. Before using scan tool, 
read its Operator’s (Instruction) Manual carefully to 
have good understanding as to what functions are 
available and how to use it.
It is indistinguishable which module turns on MIL 
because not only ECM but also TCM turns on MIL. 
Therefore, check both ECM and TCM for DTC when 
MIL lights on.
When checking TCM for DTC, keep in mind that DTC 
is displayed on the scan tool as follows depending on 
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– OBD generic scan tool displays DTC detected by 

each of ECM and TCM simultaneously.

• When replacing TCM with used one, all learned 

controls which are stored in TCM memory should be 
erased after the replacement referring to “Learning 
Control Initialization”. Neglecting this initialization may 
cause excessive shift shock.

• Be sure to read “Precaution for CAN Communication 

System in Section 00” before inspection and observe 
what is written there.

• TCM and/or ECM replacement:

When substituting a known-good TCM and/or ECM, 
check for the following conditions.
Neglecting this check may result in damage to a good 
TCM and/or ECM.
– All relays and actuators have resistance of 

specified value.

– MAF sensor, Manifold absolute pressure (MAP) 

sensor, TP sensor and fuel tank pressure sensor 
are in good condition. Also, the power circuit of 
these sensors is not shorted to the ground.

• Communication of ECM, BCM, combination meter, 

keyless start control module (if equipped), ABS/ESP

® 

control module, 4WD control module (if equipped), 
TCM and steering angle sensor (ESP

® model), is 

established by CAN (Controller Area Network). (For 
more detail of CAN communication for ECM, refer to 
“CAN Communication System Description”). 
Therefore, handle CAN communication line with care 
referring to “Precautions for Installing Mobile 
Communication Equipment in Section 00”.

General Service Procedure Information

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When repairing automatic transmission, it is necessary 
to conduct the on-vehicle test to investigate where the 
cause of the trouble lies first.
Then whether overhaul should be done or not is 
determined. If the transmission is disassembled without 
such preliminary procedure, not only the cause of the 
trouble would be unknown, but also a secondary trouble 
may occur and often time would be wasted.

Precautions for Disassembly and Reassembly

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As the automatic transmission consists of high precision 
components, the following cautions should be strictly 
observed when handling its parts in disassembly and 
reassembly.
• Disassembling valve body assembly is prohibited in 

principle. However, a few parts can be disassembled.
When disassembling valve body component parts, 
confirm whether these parts are allowed to 
disassemble or not referring to “Valve Body Assembly 
Components”.

• Make sure to wash dirt off from the transmission so 

that no such dirt will enter the transmission during 
dismounting and remounting.

• 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.

• Make sure to wash dirt off from the transmission so 

that no such dirt will enter the transmission during 
disassembly and reassembly.

• 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 15 

minutes before use.

5A-2 Automatic Transmission/Transaxle: 

Part Inspection and Correction Table

General Description

Automatic Transmission Description

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• This automatic transmission is a full automatic type with 4-speed plus overdrive (O/D).

The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-
up mechanism. The gear shift device consists of 3 sets of planetary gear units, 3 disc type clutches, 4 disc type 
brakes and 3 one-way clutches. The gear shift is done by selecting one of 7 positions (“P”, “R”, “N”, “D”, “4”, “3” and 
“L”) by means of the select lever installed on the floor.

• This automatic transmission has the clutch-to-clutch (brake) control function when the gear is upshifted from the 4th 

gear to the 5th gear and downshifted from the 5th gear to the 4th gear. With this function, gears are synchronized by 
controlling the hydraulic pressure to the forward clutch and No.1 brake without using the one-way clutch. This 
automatic transmission also has the line pressure learning control function to achieve gear changes smoothly. 
Therefore, when any of the following conditions applies, initialize the line pressure learning control of TCM referring 
to “Learning Control Initialization”. Neglecting this initialization may cause excessive shift shock.

• The A/T unit has been overhauled
• The A/T unit has been replaced
• The engine has been overhauled
• The engine has been replaced
• TCM has been replaced with used one

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.

Automatic Transmission/Transaxle:  5A-3

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

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1. Torque converter clutch (TCC)

7. 2nd brake

13. One-way No.3 clutch

2. Torque converter

8. One-way No.1 clutch

14. 1st and reverse brake

3. Direct clutch

9. Front planetary gear

15. Rear planetary

4. Reverse clutch

10. No.1 brake

16. Input shaft

5. Forward clutch

11. Middle planetary gear

17. Intermediate shaft

6. One-way No.2 clutch

12. No.2 brake

18. Output shaft