Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 84

5A-35 Automatic Transmission/Transaxle: 

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.

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

I5JB0A510160-01

2

1

3

4

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1

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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.)

IYSQ01510241-01

IYSQ01510242-01

Automatic Transmission/Transaxle:  5A-36

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.

13) After confirming that lugs of all brake plates and 

brake discs are in grooves securely, hold retaining 
ring (1) of planetary sun gear, install center support 
assembly by aligning bolt holes (2) in center support 
and transmission case.

NOTE
Unless retaining ring of planetary sun gear is 
held, brake valve gets off center support and 
that will make it impossible to align fluid 
holes with bolt holes.

 

14) Tighten center support bolts by certain amount at a 

time till specified tightening torque is obtained.

Tightening torque
Center support bolt:  26 N·m (2.6 kgf-m, 19.0 lb-
ft)

15) Install direct clutch assembly by aligning splines in 

direct clutch cylinder with planetary sun gear.

NOTE
Ends of splines in direct clutch cylinder and 
planetary sun gear should come almost in 
match.

 

16) Apply grease to thrust bearing (1) and bearing races 

(2), and then install them to direct clutch.

1

I5JB0A510132-01

1

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1

2

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2

1

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5A-37 Automatic Transmission/Transaxle: 

17) Install forward clutch assembly by putting all lugs of 

direct clutch disc hub together and matching them 
with groove cut in direct clutch input hub, and at the 
same time aligning splines in forward clutch hub with 
inner shaft.

NOTE
Use care not to let forward clutch rear No.1 
race and thrust bearing installed to forward 
clutch hub fall off.

 

18) When clutch disc and plate have been replaced, 

check height difference between forward clutch input 
shaft and transmission case (1) by measuring as 
shown in the figure.

NOTE
If measured value is less than standard 
value, remove forward clutch assembly and 
install it again.

 

Standard height difference between forward 
clutch input shaft and transmission case
“a”: About 2.0 mm (0.079 in.)

19) Apply grease to thrust bearing (1) and bearing race 

(2), and then install them to forward clutch input 
shaft.

20) Install O/D case by aligning cutout in O/D case (1) 

and that in transmission case.

NOTE
Use care not to drop thrust rear race installed 
to O/D case.

 

21) Apply grease to thrust washers (1) and install them 

to O/D planetary gear (2) and planetary ring gear (3), 
and then install O/D input shaft assembly to O/D 
case.

NOTE

• Fit claws of thrust washer into holes 

securely.

• Use care not to drop thrust washer 

installed to O/D planetary gear.

 

2. Forward clutch

IYSQ01510249-01

2

1

“a”

I5JB0A510135-01

2. Cutout in automatic transmission

2

1

I5JB0A510136-01

1

2

I5JB0A510137-02

I5JB0A510138-01

Automatic Transmission/Transaxle:  5A-38

22) When clutch disc or plate has been replaced, check 

height difference between O/D case (1) and O/D 
clutch cylinder (2) by measuring it as shown in the 
figure.

NOTE
Measure at the highest point along inner 
circumference of O/D clutch cylinder.

 

Standard height difference between O/D case 
and O/D clutch cylinder
“a”: About 3.5 mm (0.138 in.)

23) Apply A/T fluid to new housing O-ring and install it to 

O/D case. Then install converter housing (1) and 
tighten housing bolt to specified torque.

Tightening torque
Torque converter housing bolt (a):  35 N·m (3.5 
kgf-m, 25.5 lb-ft)
Torque converter housing bolt (b):  58 N·m (5.8 
kgf-m, 42.0 lb-ft)

24) Apply grease to bearing race (1) and thrust bearing 

(2) and install them to O/D clutch cylinder.

25) Apply A/T fluid to new oil pump cover O-ring and 

install it to oil pump assembly. Then install oil pump 
assembly aligning bolt holes in O/D case with those 
in transmission case oil pump assembly. Apply seal 
packing to oil pump assembly bolts and tighten them 
by certain amount of torque at each time one after 
another till specified torque is attained.

Tightening torque
Oil pump bolt (a):  22 N·m (2.2 kgf-m, 16.0 lb-ft)

26) Apply 2 – 4 kg/cm

2

 air pressure into fluid holes in the 

figure as numbered and check operation sound of 
each part.

27) Take clown transmission from stand and install new 

gasket and cover plate (1).

I5JB0A510161-01

I5JB0A510162-01

1

2

I5JB0A510139-01

1. O/D clutch

5. Second coast brake

2. O/D brake

6. Second brake

3. Forward clutch

7. Reverse brake

4. Direct clutch

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IYSQ01510258-01

1

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