Transmission Assembly (1)

WARNING: This page is about a different variant/trim than selected.

Drive manual shaft oil seals into the transmission case until they are flush using suitable tool.

Fig 1: Tapping Manual Shaft Oil Seals
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Apply ATF to manual shaft oil seals.
- Do not reuse manual shaft oil seals.
Install detent spring and spacer in transmission case and secure with the bolt.

Fig 2: Locating Detent Spring And Spacer
Courtesy of SUZUKI OF AMERICA CORP.

Bolt: 7.9 N.m (0.81 kg-m, 70 in-lb)
Install manual shaft to transmission case.

Fig 3: Installing Manual Shaft To Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
Install parking rod to manual plate.

Fig 4: Installing Parking Rod To Manual Plate
Courtesy of SUZUKI OF AMERICA CORP.
Install manual plate (with parking rod) to manual shaft.

Fig 5: Installing Manual Plate (With Parking Rod) To Manual Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install retaining pin into the manual plate and manual shaft.

Fig 6: Identifying Retaining Pin And Manual Plate
Courtesy of SUZUKI OF AMERICA CORP.
1. Align pinhole of the manual plate to pinhole of the manual shaft using suitable tool.
2. Tap the retaining pin into the manual plate using suitable tool.
  CAUTION:
  - Drive retaining pin to 2±0.5 mm (0.08±0.020 in) over the manual plate.
  - Do not reuse retaining pin.
Install retaining pin into the transmission case and manual shaft.

Fig 7: Aligning Pinhole Of Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
1. Align pinhole of the transmission case to pinhole of the manual shaft using suitable tool.
2. Tap the retaining pin into the transmission case using suitable tool.
  CAUTION:
  - Drive retaining pin to 5±1 mm (0.20±0.04 in) over the transmission case.
  - Do not reuse retaining pin.
Install O-rings to servo assembly.

Fig 8: Installing O-Rings To Servo Assembly
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse O-rings.
- Apply petroleum jelly to O-rings.
Install return spring to servo assembly.

Fig 9: Installing Return Spring To Servo Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install servo assembly in transmission case.

Fig 10: Installing Servo Assembly In Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
Install snap ring to transmission case using suitable tool.

Fig 11: Installing Snap Ring To Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
Install D-rings in reverse brake piston.

Fig 12: Identifying Reverse Brake Piston D-Rings
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse D-rings.
- Apply ATF to D-rings.
Install reverse brake piston in transmission case.

Fig 13: Identifying Reverse Brake Piston
Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing to drum support edge surface.

Fig 14: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to needle bearing.
Install seal rings to drum support.

Fig 15: Identifying Seal Rings
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse seal rings.
- Apply petroleum jelly to seal rings.
Install spring retainer and return spring in transmission case.

Fig 16: Identifying Spring Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Install snap ring in transmission case while compressing return spring using Tool.

Fig 17: Compressing Return Spring
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: KV31102400 (J-34285 and J-34285-87)

CAUTION: Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.
Install reverse brake drive plates driven plates and dish plates in transmission case.

Fig 18: Identifying Snap Ring, Retaining Plate, Drive Plate And Dish Plate
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Take care with order of plates.
- VQ40DE models
  - Snap ring (1)
  - Retaining plate (2)
  - Drive plate (3)
  - Driven plate (4)
  - Dish plate (5)
  - Driveplate/Driven plate:6/6
Assemble N-spring.

Fig 19: Identifying Driven Plate, Transmission Case And N-Spring
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse brake retaining plate in transmission case.
Install snap ring in transmission case.

Fig 20: Identifying Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Measure clearance (A) between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.

Fig 21: Measuring Clearance Between Retaining Plate And Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.

Clearance "A": 0.7 - 1.1 mm (0.028 - 0.043 in)

Retaining plate: Refer to [SERVICE DATA AND SPECIFICATIONS ].
Install needle bearing to transmission case.

Fig 22: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Take care with the direction of needle bearing. Refer to [LOCATION OF ADJUSTING SHIMS, NEEDLE BEARINGS, THRUST WASHERS AND SNAP RINGS ].
- Apply petroleum jelly to needle bearing.
Install revolution sensor to transmission case and tighten bolt to specified torque.

Fig 23: Locating Revolution Sensor
Courtesy of SUZUKI OF AMERICA CORP.

Revolution sensor bolt: 5.8 N.m (0.59 kg-m, 51 in-lb)
CAUTION:
- Do not subject sensor to impact by dropping or hitting it.
- Do not disassemble sensor.
- Do not allow metal filings or any foreign material to get on the sensor's front edge magnetic area.
- Do not place sensor in an area affected by magnetism.
Install new rear oil seal until it is flush into the rear extension case (2WD models) using Tool or adapter case (4WD models) using suitable tool.

Fig 24: Tapping Rear Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: ST33400001 (J-26082)
CAUTION:
- Apply ATF to rear oil seal.
- Do not reuse rear oil seal.
Install return spring (1) to parking pawl (2).

Fig 25: Identifying Return Spring And Parking Pawl
Courtesy of SUZUKI OF AMERICA CORP.
Install parking pawl (with return spring) and pawl shaft to rear extension (2WD models) or adapter case (4WD models).

Fig 26: Installing Parking Pawl (With Return Spring) And Pawl Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install parking actuator support to rear extension (2WD models) or adapter case (4WD models).

Fig 27: Installing Parking Actuator Support
Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing (1) to rear extension (2WD models) or adapter case (4WD models).

Fig 28: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to needle bearing.
Install seal rings to output shaft.

Fig 29: Identifying Output Shaft Seal Rings
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse seal rings.
- Apply petroleum jelly to seal rings.
Install parking gear to output shaft.

Fig 30: Installing Parking Gear To Output Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install output shaft in transmission case.

Fig 31: Installing Output Shaft In Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not mistake front of shaft for rear because both sides look similar (thinner end is front side).
Install bearing race to output shaft.

Fig 32: Installing Bearing Race To Output Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install rear extension assembly (2WD models) or adapter case assembly (4WD models) according to the following procedures.
1. 2WD models
  
  Fig 33: Identifying Sealant Applying Area
  Courtesy of SUZUKI OF AMERICA CORP.
  1. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ]) to rear extension assembly as shown.
    CAUTION: Completely remove all moisture, oil, old sealant and any foreign material from the transmission case and rear extension assembly mating surfaces.
  2. Install rear extension assembly to transmission case.
    
    Fig 34: Installing Rear Extension Assembly
    Courtesy of SUZUKI OF AMERICA CORP.
    
    CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.
  3. Install the bracket (1), (2) and rear extension assembly bolts and tighten to the specified torque.
    
    Fig 35: Identifying Rear Extension Assembly Bolts
    Courtesy of SUZUKI OF AMERICA CORP.
    - Self sealing bolt (3)
    - Bolt (A)
      Rear extension assembly bolt: 52 N.m (5.3 kg-m, 38 ft-lb)
      
      Self-sealing bolt: 61 N.m (6.2 kg-m, 45 ft-lb)
      
      CAUTION: Do not reuse self-sealing bolt.
2. 4WD models
  
  Fig 36: Installing Gasket Onto Transmission Case
  Courtesy of SUZUKI OF AMERICA CORP.
  1. Install gasket onto transmission case.
    CAUTION:
    Completely remove all moisture, oil, old gasket and any foreign material from the transmission case and adapter case assembly mating surfaces.
    
    Do not reuse gasket.
  2. Install adapter case assembly to transmission case.
    
    Fig 37: Installing Adapter Case Assembly To Transmission Case
    Courtesy of SUZUKI OF AMERICA CORP.
    
    CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.
  3. Tighten adapter case assembly to specified torque.
    
    Fig 38: Locating Adapter Case Assembly Bolts
    Courtesy of SUZUKI OF AMERICA CORP.
    - 1: ==>
    - 2: Brackets
    - 3: Self-sealing bolts
      CAUTION: Do not reuse self-sealing bolt (2).
      
      Adapter case assembly bolt: 52 N.m (5.3 kg-m, 38 ft-lb)
      
      Self-sealing bolt: 61 N.m (6.2 kg-m, 45 ft-lb)
Install direct clutch assembly in reverse brake.

Fig 39: Identifying Direct Clutch Assembly
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.
Install needle bearing in drum support.

Fig 40: Identifying Needle Bearing And Drum Support
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to needle bearing.
Install high and low reverse clutch assembly in direct clutch.

Fig 41: Identifying High And Low Reverse Clutch Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Align the drive plate using suitable tool.

Fig 42: Identifying Drive Plate
Courtesy of SUZUKI OF AMERICA CORP.
Install high and low reverse clutch hub, mid sun gear assembly and rear sun gear assembly as a unit.

Fig 43: Identifying Mid Sun Gear And Rear Sun Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Make sure that portion "A" of high and low reverse clutch drum protrudes approximately 2 mm (0.08 in) beyond portion "B" of rear sun gear.

Fig 44: Identifying High And Low Reverse Clutch Drum
Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing in rear carrier assembly.

Fig 45: Installing Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to needle bearing.
Install bearing race in rear carrier assembly.

Fig 46: Installing Bearing Race
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to bearing race.
Install rear carrier assembly in direct clutch drum.

Fig 47: Identifying Rear Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing (rear side) to mid carrier assembly.

Fig 48: Installing Needle Bearing (Rear Side)
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to needle bearing.
Install needle bearing (front side) to mid carrier assembly.

Fig 49: Installing Needle Bearing (Front Side)
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to needle bearing.
Install mid carrier assembly in rear carrier assembly.

Fig 50: Identifying Mid Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install front carrier assembly, input clutch assembly and rear internal gear as a unit.

Fig 51: Identifying Front Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install seal rings in input clutch assembly.

Fig 52: Identifying Seal Rings
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse seal rings.
- Apply petroleum jelly to seal rings.
Install band servo anchor end pin and lock nut in transmission case.

Fig 53: Identifying Band Servo Anchor End Pin
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not reuse band servo anchor end pin.
Install brake band in transmission case.

Fig 54: Identifying Servo Assembly Incorrect Installation
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Install it so that the identification to avoid incorrect installation faces the servo side.
Install front sun gear to front carrier assembly.

Fig 55: Installing Front Sun Gear To Front Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply ATF to front sun gear bearing and 3rd one-way clutch end bearing.
Install needle bearing to front sun gear.

Fig 56: Identifying Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to needle bearing.
Adjust brake band tilting using a clip so that brake band contacts front sun gear drum evenly.

Fig 57: Adjusting Brake Band
Courtesy of SUZUKI OF AMERICA CORP.
Adjust brake band.

Fig 58: Identifying Servo Assembly Incorrect Installation
Courtesy of SUZUKI OF AMERICA CORP.
1. Loosen lock nut.
2. Tighten band servo anchor end pin to specified torque.
  Anchor end pin: 5.0 N.m (0.51 kg-m, 44 in-lb)
3. Back off band servo anchor end pin three turns.
4. Holding band servo anchor end pin, tighten lock nut to specified torque.
  Lock nut: 46 N.m (4.7 kg-m, 34 ft-lb)