Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 330

5A-111 Automatic Transmission/Transaxle: 

Oil Pump Inspection

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• Check seal ring (2) and bushing (1) for wear and 

damage.

• Check clearance between outer gear (1) and body.

Clearance between outer gear and body
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
Service limit: 0.30 mm (0.0118 in.)

• Check tip clearance between inner gear (1) and outer 

gear.

Tip clearance between inner gear and outer gear
Standard: 0.11 – 0.14 mm (0.0043 – 0.0055 in.)
Service limit: 0.30 mm (0.0118 in.)

NOTE
Measure with torque converter installed.

 

• Check side clearance between inner gear/outer gear 

and pump body.

Side clearance between inner gear / outer gear 
and pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.0020 in.)
Service limit: 0.1 mm (0.0039 in.)

• Measure inside diameter of oil pump body bushing.

If inside diameter exceeds limit, replace oil pump 
body.

Oil pump body bushing inside diameter standard
38.113 – 38.138 mm (1.5005 – 1.5014 in.)

• Measure inside diameter of stator shaft assembly 

bushing.
If inside diameter exceeds limit, replace stator shaft 
assembly.

Stator shaft assembly bushing inside diameter 
standard
Front side (2): 21.501 – 21.527 mm (0.8465 – 0.8475 
in.)
Rear side (1): 23.025 – 23.051 mm (0.9065 – 0.9075 
in.)

1

2

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Automatic Transmission/Transaxle:  5A-112

Overdrive (Planetary Gear Side) Components

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Overdrive (Planetary Gear Side) Disassembly 
and Assembly

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Disassembly

1) With overdrive (O/D) clutch cylinder (1) held 

stationary, turn O/D input shaft (2) clockwise to 
check that it turns smoothly and then 
counterclockwise to check that it locks.

12

7

6

4

3

1

1

14

14

8

11

11

15

14

13

11

2

5

FLD

9

FLD

10

FLD

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1. Bearing

5. O-ring

9. Clutch plate

13. One-way clutch

: Apply A/T fluid.

2. Race

6. Return spring

10. Clutch disc

14. Thrust washer

3. Clutch cylinder

7. Snap ring

11. Retaining ring

15. O/D planetary gear

4. Clutch piston

8. Cushion clutch plate

12. Brake hub

: Do not reuse.

[A]: Rotates
[B]: Locks

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5A-113 Automatic Transmission/Transaxle: 

2) Remove O/D planetary gear assembly (1).

3) With O/D clutch assembly (2) installed to oil pump, 

apply compressed air (400 – 800 kPa, 4 – 8 kg/cm

2

, 

57 – 113 psi) to oil hole (3) in oil pump (1) and 
measure stroke of clutch piston. If it is not within 
standard range, replace cushion clutch plate or 
clutch disc.

Standard stroke of clutch piston
1.74 – 2.44 mm (0.069 – 0.096 in.)

4) Remove retaining ring (1) and then remove brake 

hub (2).

5) Remove retaining ring (1) cushion plate (2), clutch 

plate (3) and clutch disc (4) in that order.

6) With clutch piston return spring compressed with 

special tools, remove clutch piston return spring.

Special tool
(A):  09918–48211 
(B):  09926–98320 
(C):  09918–48220 

7) Install O/D clutch cylinder to oil pump (2). Apply 

compression air into fluid hole (3) in oil pump (2) and 
remove clutch piston (1).

8) Remove piston inner O-ring and piston outer O-ring 

from clutch piston (1).

9) Remove retaining ring from O/D planetary gear and 

then remove one-way clutch, thrust washer and 
thrust bearing.

2. O/D clutch cylinder

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2

3

1

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1

2

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1

4

3

2

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1. Snap ring

(C)

1

(A)

(B)

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1

2

3

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Automatic Transmission/Transaxle:  5A-114

Assembly
Assemble each component by reversing removal 
procedure and noting the following points.
• When installing thrust washer (1), bring its oil groove 

(3) to the front.

• When installing one-way clutch to one-way clutch 

outer race, bring its flange (2) to the front.

• Before installing piston inner O-ring and piston outer 

O-ring, apply A/T fluid to them.

• Install so that snap opening and projection (1) of 

clutch piston return spring will not match.

• Install retaining clutch ring and retaining brake hub so 

that their slots (2) will not match with dent (1) in O/D 
clutch cylinder.

• For installing cushion clutch plate (1), refer to the 

figure.

Overdrive (Planetary Gear Side) 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.

 

• Check that ball valve of clutch piston is not stuck.
• Check valve for leakage by applying low pressure air 

into ball valve hale.

[A]: Front

2. Slot

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2. Clutch cylinder side
3. Brake hub side

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