Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 331

5A-115 Automatic Transmission/Transaxle: 

• Measure free length of piston return spring.

Standard free length of O/D clutch piston return 
spring
16.9 mm (0.665 in.)

• Measure inside diameter of planetary gear bushing. If 

inside diameter exceeds limit, replace planetary gear.

Planetary gear bushing inside diameter standard
11.200 – 11.221 mm (0.4409 – 0.4418 in.)

Overdrive (Case Side) Components

S6JB0A5106036

I5JB0A510171-01

I5JB0A510149-01

1

FLD

13

FLD

12

FLD

6

FLD

8

7

9

5

2

3

4

3

2

10

11

10

I5JB0A510103-01

1. Sealing

4. O/D case

7. Brake piston

10. Retaining ring

13. Brake plate

2. Bearing

5. Planetary ring gear

8. Return spring

11. Brake backing plate

: Do not reuse.

3. Bearing race

6. O-ring

9. Thrust washer

12. Brake disc

: Apply A/T fluid.

Automatic Transmission/Transaxle:  5A-116

Overdrive (Case Side) Disassembly and 
Assembly

S6JB0A5106037

Disassembly

1) Remove retaining ring (1), brake backing plate (2), 

brake disc (3) and brake plate (4) in that order. Then 
remove planetary ring gear, thrust bearing race and 
thrust bearing.

2) Remove retaining ring and piston return spring using 

special tool and press (1).

Special tool
(A):  09926–96510

CAUTION

!

 

Be careful when applying pressure, for 
overpressure will cause plate section of 
piston return spring to deform.

 

3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm

2

, 

57 – 113 psi) to oil hole (1) in O/D case (2) and 
remove brake piston.

4) Remove brake piston inner ring and brake piston 

outer ring from brake piston.

5) Unsnap seal ring (1).
6) Remove 2 seal rings (1).

NOTE
Be careful not to open seal ring more than 
necessary.

 

1

2

3

4

I5JB0A510104-01

1

(A)

I5JB0A510105-01

1

2

I5JB0A510106-01

IYSQ01510138-01

5A-117 Automatic Transmission/Transaxle: 

Assembly
Install each component by reversing removal procedure 
and noting the following points.
• When installing rear seal ring, use care not to open it 

too wide.

• Apply A/T fluid to O-ring, disc, etc. before installing 

them.

• Opening of retaining brake front ring (2) and 

projection (1) of O/D case should be matched.

• When installing each component, refer to “Overdrive 

(Case Side) Components”.

• Measure clearance between retaining ring (1) and 

brake backing plate (2) with thickness gauge.
If the clearance is out of specification, select another 
plate with suitable thickness from the list below and 
replace it.

Standard clearance between retaining ring and 
brake backing plate
0.40 – 1.38 mm (0.016 – 0.054 in.)

Overdrive (Case Side) Inspection

S6JB0A5106038

• Measure free length of piston return spring.

Standard free length of O/D brake piston return 
spring
15.10 mm (0.594 in.)

• 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.

 

Thickness

1.95 – 2.05 mm (0.077 – 0.081 in.)
2.25 – 2.35 mm (0.089 – 0.093 in.)

IYSQ01510139-01

IYSQ01510134-01

I5JB0A510171-01

I4JA01512210-01

Automatic Transmission/Transaxle:  5A-118

Forward Clutch Components

S6JB0A5106039

Forward Clutch Disassembly and Assembly

S6JB0A5106040

Disassembly

1) After removing retaining ring (1), remove direct 

clutch hub (2) and forward clutch hub (3).

2) Remove bearing race (1) and thrust bearing (2).

3) Remove retaining ring (1) and then remove all clutch 

discs.

1

2

3

4

5

5

5

6

7

8

9

10

11

FLD

FLD

FLD

I5JB0A510108-01

1. Input shaft

5. Retaining ring

9. Clutch disc

: Apply A/T fluid.

2. Piston

6. Bearing race

10. Froward clutch hub

3. Return spring

7. Bearing

11. Direct clutch hub

4. O-ring

8. Clutch plate

: Do not reuse.

IYSQ01510143-01

I5JB0A510109-01

IYSQ01510147-01