Suzuki Grand Vitara JB627. Manual - part 237

5A-132 Automatic Transmission/Transaxle: 

35) Measure forward clutch pack clearance (A) by 

applying compressed air (392 kPa, 4.0 kg/cm

2

, 57 

psi) into oil hole, (1) of input shaft as shown in figure.

Pack Clearance
0.4 – 0.7 mm (0.016 – 0.027 in.)

NOTE
Install a selective flange (t 3.4 mm) when 
measuring the moving distance. (shaded 
area in figure.)

 

• Flange moving distance A: 0.12 – 1.19 mm 

(0.00472 – 0.0468 in.)
Pack Clearance: Flange moving distance A – 0.01 
mm (0.00039 in.)
If pack clearance is out of specification, select 
another flange with suitable thickness from the list 
below and replace it.

Available forward clutch flange thickness

36) Install input shaft assembly (1) to clutch drum 

assembly.

37) Install thrust needle roller bearing (1) to clutch drum 

assembly.

38) Install thrust bearing race No.2 (1) and input shaft 

thrust bearing race (2) to forward clutch hub.

39) Install forward clutch hub (1) to clutch drum 

assembly.

Identification 

No.

Thickness

Identification 

No.

Thickness

0

3.0 mm 

(0.118 in.)

6

3.6 mm 

(0.142 in.)

1

3.1 mm 

(0.122 in.)

7

3.7 mm 

(0.146 in.)

2

3.2 mm 

(0.126 in.)

8

3.8 mm 

(0.150 in.)

3

3.3 mm 

(0.130 in.)

9

3.9 mm 

(0.154 in.)

4

3.4 mm 

(0.134 in.)

A

4.0 mm 

(0.158 in.)

5

3.5 mm 

(0.138 in.)

—

—

1

A

I4JA01512199-01

1

I4JA01512200-01

1

I4JA01512201-01

2

1

I4JA01512202-01

1

I4JA01512203-01

Automatic Transmission/Transaxle:  5A-133

40) Install 2 thrust needle roller bearings (1) to direct 

clutch hub.

41) Install direct clutch hub (1) to clutch drum assembly.

42) Install reverse clutch plates “P” and reverse clutch 

discs “D” to reverse clutch hub in the following order.
D - P - D - P - D - P - D - P - D

43) Install reverse clutch flange “F”.
44) Install clutch cushion plate (1) to reverse clutch hub 

as shown in figure.

45) Install reverse clutch reaction sleeve (1) to reverse 

clutch hub.

46) Install reverse clutch hub sub assembly (1) including 

reverse clutch reaction sleeve, clutch cushion plate, 
reverse clutch flange, 4 reverse clutch discs and 3 
reverse clutch plates to clutch drum assembly.

47) Install snap ring (1) on clutch drum and input shaft 

assembly by using flat end rod or the like.

1

I4JA01512204-01

1

I4JA01512205-01

1

P

D

F

I6JB01510042-01

1

I4JA01512207-01

1

I4JA01512208-01

1

I4JA01512209-01

5A-134 Automatic Transmission/Transaxle: 

Clutch Drum & Input Shaft Assembly Inspection

S6JB0B5106038

• Check that sliding surface of discs, plate and flange 

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 reverse clutch hub 

bushing. If inside diameter exceeds limit, replace 
reverse clutch hub.

Reveres clutch hub bushing inside diameter
Standard: 35.812 – 35.837 mm (1.4099 – 1.4109 in.)
Limit: 35.887 mm (1.4129 in.)

• Measure inside diameter of direct clutch hub bushing. 

If inside diameter exceeds limit, replace direct clutch 
hub.

Direct clutch hub bushing inside diameter
Standard: 26.037 – 26.062 mm (1.0251 – 1.0261 in.)
Limit: 26.112 mm (1.028 in.)

• Measure free length of forward clutch return spring 

including spring seat.

Forward clutch return spring free length
“a”: 26.74 mm (1.053 in.)

NOTE

• Do not apply excessive force when 

measuring spring free length.

• Perform measurement at several points.

 

I4JA01512210-01

I4JA01512211-01

I4JA01512212-01

 

“a”

I4JA01512213-01

Automatic Transmission/Transaxle:  5A-135

• Measure free length reverse clutch return spring 

including spring seat.

Reverse clutch return spring free length
“a”: 21.04 mm (0.828 in.)

NOTE

• Do not apply excessive force when 

measuring spring free length.

• Perform measurement at several points.

 

• Measure free length direct clutch return spring 

including spring seat.

Direct clutch return spring free length
“a”: 19.51 mm (0.768 in.)

NOTE

• Do not apply excessive force when 

measuring spring free length.

• Perform measurement at several points.

 

 

“a”

I4JA01512214-01

 

“a”

I4JA01512215-01