Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 85

5A-39 Automatic Transmission/Transaxle: 

28) Measure clearance in shaft direction by applying dial 

gauge (1) to output shaft as shown in the figure.

Standard clearance in shaft direction
0.3 – 0.9 mm (0.012 – 0.035 in.)

29) Check that inner shaft runs smoothly.
30) Apply grease to lip of new oil lip seal and drive in oil 

lip seal with special tool till it contacts transmission 
case.

Special tool
(A):  09923–46020 

31) Install a new spacer (1) to manual shift lever (2).
32) Install manual shift shaft (3) to transmission case 

through manual shift lever.

33) Drive in manual shift lever pin (1) by using hammer.

34) Align hole in sleeve cover with dent in manual shift 

lever and caulk securely with pin punch (1). Then 
check that manual shift shaft turns smoothly.

35) Install parking lock pawl (2), parking pawl pin (1) and 

parking pawl spring (3).

36) Connect parking lock rod (2) to manual shift lever (1) 

as shown in the figure.

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2

1

3

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1

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1

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2

1

3

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1

2

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Automatic Transmission/Transaxle:  5A-40

37) Install parking lock pawl bracket (1).

Tighten parking pawl bracket bolts (2) to specified 
torque.

Tightening torque
Parking pawl bracket bolt (a):  7.4 N·m (0.74 kgf-
m, 5.5 lb-ft)

38) Apply A/T fluid to new O-ring and spring and install 

them to accumulator piston and install accumulator 
piston to transmission case.

Accumulator spring specification

39) After confirming that accumulator piston is pushed all 

the way down, match pin of manual shift lever with 
groove in manual valve.

40) Fix valve body (1) by using bolts with each nominal 

length as indicated in the figure and tightening to 
specified torque.

Tightening torque
Valve body bolt:  10 N·m (1.0 kgf-m, 7.5 lb-ft)

Valve body bolt nominal length
“a”: 28 mm (1.10 in.)
“b”: 30 mm (1.18 in.)
“c”: 36 mm (1.42 in.)
“d”: 45 mm (1.77 in.)

41) Install O/D brake applying tube (1).

Accumulator 

piston

Accumulator spring

Spring free 

length “a”

Color

Forward clutch

75.03

White + Blue

Direct clutch

57.74

White + Purple

Second brake

56.16

Purple

1. Forward clutch accumulator piston
2. Direct clutch accumulator piston
3. Second brake accumulator piston
4. Accumulator spring

1

2, (a)

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4

3

1

2

“a”

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“a”

“a”

“a”

1

“b”

“b”

“c”

“c”

“c”

“d”

“d”

“d”

“d”

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1

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5A-41 Automatic Transmission/Transaxle: 

42) Lubricate new O-ring with A/T fluid and attach it to 

grommet of solenoid wire harness. Then connect 
solenoid wire harness to transmission case and fix it 
with solenoid wire harness clamp. Connect each 
connector to solenoid. And install new gasket and 
brake applying cover.

Tightening torque
Transmission wire connector bolt (a):  16 N·m (
1.6 kgf-m, 11.5 lb-ft)

43) Connect solenoid coupler to each solenoid.
44) Install oil strainer (1) to valve body assembly.

Tightening torque
Oil strainer bolt (a):  5.5 N·m (0.55 kgf-m, 4.0 lb-
ft)

45) Install transmission oil pan (1) with new oil pan 

gasket.

NOTE
Align cutout in oil pan gasket with that in 
transmission case.

 

Tightening torque
Transmission oil pan bolt:  4.5 N·m (0.45 kgf-m, 
3.5 lb-ft)

46) With wood rough key attached to output shaft, install 

sensor rotor (2) by aligning its key groove with wood 
rough key and install C-ring.

47) Install adapter case (1) with new adapter gasket to 

transmission case and tighten adapter case bolts to 
specified torque.

Tightening torque
Adapter case bolt (a):  31 N·m (3.1 kgf-m, 30.0 lb-
ft)

48) Apply A/T fluid to new O-rings and install them to 

input shaft speed sensor (1) and output shaft speed 
sensor (2), and then install input shaft speed sensor 
(1) and output shaft speed sensor (2).

(a)

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1

(a)

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1. C-ring

1

2

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1

(a)

(a)

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1

2

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Automatic Transmission/Transaxle:  5A-42

49) After turning manual shift shaft fully rearward, turn it 

back by 2 notches and set it to “N” range. Then 
install shift switch, lock washer and nut and tighten 
nut. After tightening it, bend claws of lock washer.

Tightening torque
Manual shift shaft nut (a):  12.5 N·m (1.25 kgf-m, 
9.0 lb-ft)

50) With neutral reference line (1) and cut groove (2) in 

switch aligned, tighten lock bolt.

Tightening torque
Transmission range sensor bolt (b):  5.3 N·m (
0.53 kgf-m, 4.0 lb-ft)

51) Confirm that torque converter is fully fitted in 

transmission. Confirmation can be done by 
measuring dimension between end surface of 
housing case (2) and drive plate installation seat.

Standard dimension between end surface of 
case housing and drive plate installation seat “a”
17.4 mm (0.69 in.)

52) Check that torque converter turns smoothly and 

apply grease to center piece (1) of torque converter.

(b)

1

2

(a)

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