Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 335

5A-131 Automatic Transmission/Transaxle:

Assembly
Assemble components by reversing disassembly
procedure and noting the following points.
• Refer to “Planetary Gears and Output Shaft

Components” when installing each component.

• Check seal ring for damage before installation and

replace if damaged.

• Install planetary sun gear as shown in the figure.

NOTE
A is longer than B.

• Fit retaining rings into groove securely.
• Install one-way clutch as shown in the figure.

• Install reverse brake reaction plate (2) to front

planetary gear (1).
With reverse brake reaction plate (2) fixed stationary,
turn front planetary gear (1) clockwise to check that it
locks and then counterclockwise to check that it turns
smoothly.

Planetary Gears and Output Shaft 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.

• Measure inside diameter of output shaft bushing. If

inside diameter exceeds limit, replace output shaft.

Output shaft bushing inside diameter standard
18.001 – 18.026 mm (0.7087 – 0.7097 in.)

1. Front planetary gear side

[A]: Rotates
[B]: Locks

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Automatic Transmission/Transaxle: 5A-132

Valve Body Assembly Components

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Automatic Transmission Unit Assembly

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CAUTION

When replacing pressure control solenoid
valve and/or TCC pressure control solenoid
valve, it is strictly required to replace it
together with valve body assembly as a set.
Replacing pressure control solenoid valve
and/or TCC pressure control solenoid valve
independently may cause excessive shift
shock.

1) Measure inside diameter of transmission case

bushing. If inside diameter exceeds limit, replace
transmission case.

Transmission case bushing inside diameter
standard
38.113 – 38.138 mm (1.5005 – 1.5015 in.)

(a)

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1. Manual valve

5. Plate

9. Solenoid clamp

13. Valve body assembly

2. TCC control solenoid valve

6. Shift solenoid valve A

10. Solenoid clamp bolt

: 5.5 N

⋅m (0.55 kgf-m, 4.0 lb-ft)

3. Pressure control solenoid valve

7. Shift solenoid valve B

11. Shift solenoid bolt

4. Detent spring

8. Over drive (O/D) brake apply

tube

12. Detent spring bolt

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5A-133 Automatic Transmission/Transaxle:

2) After applying A/T fluid to new O-rings, install them

to reverse brake piston (3), reaction sleeve (2) and
secondary reverse piston (1).

3) Measure free length of reverse brake piston return

spring.

Standard free length of reverse brake piston
return spring
16.84 mm (0.663 in.)

4) Install reverse brake piston assembly and brake

piston return spring to transmission case, using care
not to damage O-ring. Then install snap ring (1) with
special tools.

NOTE

• Install so that opening in snap ring (1) will

not align with any of 3 lugs of spring seat.

• Do not compress spring more than

necessary and do not allow it fall or tilt.

Special tool
(A):  09926–98320
(B):  09926–98390
(C):  09944–88210

5) Prepare a stand as shown. It is necessary because

work will be done with transmission case (1) set
upright from this step on.

NOTE

• To protect transmission case against

damage, spread cloth on stand where case
contacts.

• A stand of such size as shown in the figure

will facilitate work.

6) Install thrust bearing (1) and thrust bearing race (2)

after lubricating them with grease.

NOTE
Make sure that thrust bearing output shaft
race is installed in proper direction.

7) Install brake applying tube (1) so that its lug (2) fits in

a in transmission case (4). After installation, check
that 4 lugs (3) along the underside of brake applying
tube fit inside of reverse brake piston.

2. Nut M12 x 1.75

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(C)

(A)

(B)

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A: 50 mm (1.9 in.)

C: 400 mm (15.7 in.)

B: 350 mm (13.8 in.)

D: 200 mm (7.9 in.)

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Automatic Transmission/Transaxle: 5A-134

8) Install leaf spring (1) as shown in figure.

9) Remove reverse brake reaction plate of planetary

gear assembly and align lugs of reverse brake plate,
reverse brake disc and reverse brake backing plate.
Install planetary gear assembly to transmission case
so that aligned lugs fit in groove in transmission
case.

10) Measure clearance between reverse brake plate and

lugs of transmission case.
If measured value is less than standard range, it is
possible that something is installed improperly or
dust or fluid is on reverse brake disc, etc. If it
exceeds standard range, adjust it to standard
clearance with selective reverse brake backing
plates as shown after making sure reverse brake
disc, reverse brake plate and reverse brake backing
plate are in good condition. If the clearance is out of
specification, select another plate with suitable
thickness from the list below and replace it.

Standard clearance between reverse brake plate
and lugs of transmission case
0.52 – 1.27 mm (0.020 – 0.050 in.)

Available plate thickness

11) Install reverse brake reaction plate so that its lug with

dent (1) comes to specified position as shown in
figure.

12) Using screwdriver with vinyl tape or the like wound at

its tip, install retaining reaction plate ring (1). After
installation, check that ring is in groove securely.

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Identification No.

Thickness

No identification

2.95 – 3.05 mm

(0.116 – 0.120 in.)

“325”

3.20 – 3.30 mm

(0.126 – 0.120 in.)

“350”

3.45 – 3.55 mm

(0.136 – 0.140 in.)

“375”

3.70 – 3.80 mm

(0.146 – 0.150 in.)

“400”

3.95 – 4.05 mm

(0.156 – 0.159 in.)

“425”

4.20 – 4.30 mm

(0.165 – 0.169 in.)

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