Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 301

4F-52 Electronic Stability Program: 

Table of Contents 5- i

5

Section 5

CONTENTS

Transmission / Transaxle

Precautions .................................................5-1

Precautions............................................................. 5-1

Precautions for Transmission / Transaxle............. 5-1

Automatic Transmission/Transaxle....... 5A-1

Precautions...........................................................5A-1

Precautions in Diagnosing Trouble ..................... 5A-1
General Service Procedure Information.............. 5A-1
Precautions for Disassembly and 

Reassembly ...................................................... 5A-2

General Description .............................................5A-3

Automatic Transmission Description................... 5A-3
Clutch / Brake Functions of Automatic 

Transmission..................................................... 5A-5

Table of A/T System Component Operation ....... 5A-6
Automatic Gear Shift Table................................. 5A-7
CAN Communication System Description........... 5A-9
Electronic Shift Control Input / Output Table.....5A-11
Brake Interlock System Description ..................5A-12
A/T Diagnosis General Description ...................5A-12
On-Board Diagnostic System Description.........5A-12

Schematic and Routing Diagram......................5A-14

Electronic Shift Control Input / Output 

Diagram ..........................................................5A-14

Electronic Shift Control System Wiring 

Diagram ..........................................................5A-15

Component Location .........................................5A-17

Electronic Shift Control System Components 

Location ..........................................................5A-17

Diagnostic Information and Procedures..........5A-18

A/T System Check ............................................5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-20
Transmission Warning Light Operation Check 

(Non-E-OBD Model)........................................ 5A-20

“POWER” Lamp Operation Check .................... 5A-20
DTC Table.........................................................5A-21
DTC Check .......................................................5A-23
DTC Clearance ................................................. 5A-23
Fail Safe Table.................................................. 5A-24
Scan Tool Data ................................................. 5A-26
Visual Inspection...............................................5A-29
A/T Basic Check ...............................................5A-29
Road Test .........................................................5A-30
Manual Road Test.............................................5A-31

Stall Test ...........................................................5A-32
Time Lag Test ...................................................5A-33
Line Pressure Test ............................................5A-34
Engine Brake Test.............................................5A-35
“P” Range Test..................................................5A-36
A/T Symptom Diagnosis....................................5A-36
No Gear Shift to 4th Gear .................................5A-46
No Lock-Up Occurs...........................................5A-47
Transmission Warning Light Circuit Check – 

Light Does Not Come “ON” at Ignition Switch 
ON (Non-E-OBD Model) .................................5A-48

Transmission Warning Light Circuit Check – 

Light Remains “ON” at Ignition Switch ON 
(Non-E-OBD Model)........................................5A-48

“POWER” Light Circuit Check – Light Does 

Not Come “ON” at Ignition Switch ON.............5A-48

DTC P0705: Transmission Range Sensor 

Circuit Malfunction...........................................5A-49

DTC P0707: Transmission Range Sensor 

Circuit Low ......................................................5A-51

DTC P0712: Transmission Fluid Temperature 

Sensor “A” Circuit Low ....................................5A-53

DTC P0713: Transmission Fluid Temperature 

Sensor “A” Circuit High ...................................5A-54

DTC P0717: Input / Turbine Speed Sensor 

Circuit No Signal .............................................5A-55

DTC P0722: Output Speed Sensor Circuit No 

Signal ..............................................................5A-56

DTC P0741 / P0742: TCC Circuit 

Performance or Stuck OFF / TCC Circuit 
Stuck ON.........................................................5A-58

DTC P0751 / P0752: Shift Solenoid-A 

Performance or Stuck OFF / Shift Solenoid-
A Stuck ON .....................................................5A-59

DTC P0756 / P0757: Shift Solenoid-B 

Performance or Stuck OFF / Shift Solenoid-
B Stuck ON .....................................................5A-60

DTC P0962: Pressure Control Solenoid “A” 

Control Circuit Low..........................................5A-61

DTC P0963: Pressure Control Solenoid “A” 

Control Circuit High .........................................5A-63

DTC P0973 / P0976: Shift Solenoid “A” 

Control Circuit Low / Shift Solenoid “B” 
Control Circuit Low..........................................5A-64

5-ii Table of Contents

DTC P0974 / P0977: Shift Solenoid “A” 

Control Circuit High / Shift Solenoid “B” 
Control Circuit High .........................................5A-65

DTC P1702: Internal Control Module Memory 

Check Sum Error ............................................5A-67

DTC P1703: CAN Invalid Data - TCM...............5A-67
DTC P1723: Range Select Switch 

Malfunction......................................................5A-68

DTC P1774: CAN Communication Bus Off.......5A-69
DTC P1777: TCM Lost Communication with 

ECM (Reception Error) ...................................5A-72

DTC P1778: TCM Lost Communication with 

BCM (Reception Error) ...................................5A-73

DTC P1874: 4L Switch Circuit Malfunction 

(Short) .............................................................5A-74

DTC P1875: 4L Switch Circuit Malfunction 

(Open) .............................................................5A-75

DTC P1878: Torque Converter Clutch 

Shudder ..........................................................5A-77

DTC P2763: Torque Converter Clutch (TCC) 

Circuit High .....................................................5A-77

DTC P2764: Torque Converter Clutch (TCC) 

Circuit Low ......................................................5A-79

Inspection of TCM and Its Circuits ....................5A-80
TCM Power and Ground Circuit Check.............5A-84

Repair Instructions ............................................5A-86

A/T Fluid Level Check .......................................5A-86
A/T Fluid Change ..............................................5A-87
Manual Selector Assembly Components ..........5A-87
Manual Selector Assembly Removal and 

Installation.......................................................5A-88

Select Lever Knob Installation...........................5A-88
Manual Selector Assembly Inspection ..............5A-88
“3” Position Switch Inspection ...........................5A-88
Select Cable Component ..................................5A-89
Select Cable Adjustment...................................5A-89
Transmission Range Sensor Removal and 

Installation.......................................................5A-90

Transmission Range Sensor Inspection and 

Adjustment ......................................................5A-90

Key Interlock Cable Removal and Installation...5A-91
Brake and key Interlock System Inspection ......5A-93
Mode Select Switch Inspection .........................5A-94
Input Shaft Speed Sensor Removal and 

Installation.......................................................5A-94

Input Shaft Speed Sensor Inspection................5A-94
Output Shaft Speed Sensor Removal and 

Installation.......................................................5A-95

Output Shaft Speed Sensor Inspection.............5A-95
Oil Cooler Hose and Pipe Components ............5A-96
Oil Cooler Hose and Pipes Removal and 

Installation.......................................................5A-96

Solenoid Valves (Shift Solenoid-A, Shift 

Solenoid-B, TCC Pressure Control Solenoid 
and Pressure Control Solenoid Removal 
and Installation ................................................5A-97

Solenoid Valves (Shift Solenoid-A, Shift 

Solenoid-B, TCC Pressure Control Solenoid 
and Pressure Control Solenoid Inspection......5A-98

Transmission Fluid Temperature Sensor 

Removal and Installation.................................5A-99

Transmission Fluid Temperature Sensor 

Inspection......................................................5A-100

Transmission Control Module (TCM) 

Removal and Installation...............................5A-101

A/T Relay Inspection .......................................5A-101
Automatic Transmission Unit Components .....5A-102
Automatic Transmission Assembly 

Dismounting and Remounting.......................5A-103

Automatic Transmission Unit Disassembly .....5A-104
Oil Pump Components ....................................5A-109
Oil Pump Disassembly and Assembly ............5A-110
Oil Pump Inspection ........................................5A-111
Overdrive (Planetary Gear Side) Components 5A-112
Overdrive (Planetary Gear Side) Disassembly 

and Assembly................................................5A-112

Overdrive (Planetary Gear Side) Inspection ...5A-114
Overdrive (Case Side) Components ...............5A-115
Overdrive (Case Side) Disassembly and 

Assembly.......................................................5A-116

Overdrive (Case Side) Inspection ...................5A-117
Forward Clutch Components ..........................5A-118
Forward Clutch Disassembly and Assembly...5A-118
Forward Clutch Inspection ..............................5A-120
Direct Clutch Components ..............................5A-121
Direct Clutch Disassembly and Assembly.......5A-121
Direct Clutch Inspection ..................................5A-123
Center Support Components ..........................5A-124
Center Support Disassembly and Assembly...5A-125
Center Support Inspection ..............................5A-128
Planetary Gears and Output Shaft 

Components..................................................5A-129

Planetary Gears and Output Shaft 

Disassembly and Assembly ..........................5A-130

Planetary Gears and Output Shaft Inspection.5A-131
Valve Body Assembly Components ................5A-132
Automatic Transmission Unit Assembly..........5A-132

Specifications ...................................................5A-141

Bearing and Race Installation Specification....5A-141
Tightening Torque Specifications....................5A-142

Special Tools and Equipment .........................5A-143

Recommended Service Material .....................5A-143
Special Tool ....................................................5A-143

Manual Transmission/Transaxle ............ 5B-1

For Petrol Engine Model .........................................5B-1

General Description .............................................5B-1

Manual Transmission Construction.....................5B-1

Diagnostic Information and Procedures ............5B-2

Manual Transmission Symptom Diagnosis .........5B-2

Repair Instructions ..............................................5B-3

Manual Transmission Assembly Components ....5B-3
Gear Shift Control Lever Rear Case 

Assembly Components .....................................5B-5

Gear Shift Lever Front Case Assembly 

Components......................................................5B-6

Gear Shift Shaft and Fork Components ..............5B-7

Table of Contents 5-iii

Input Shaft Assembly, Output Shaft Assembly 

and Countershaft Assembly Components ........ 5B-8

Manual Transmission Oil Change ....................... 5B-9
Extension Case Oil Level Check....................... 5B-10
Extension Case Oil Change.............................. 5B-10
Transmission Shift Control Lever Removal 

and Installation................................................5B-11

Transmission Shift Control Lever Inspection.....5B-11
Back Up Light Switch Removal and 

Installation.......................................................5B-12

Back Up Light Switch Inspection....................... 5B-12
Gear Shift Control Lever Rear Case 

Assembly Removal and Installation ................5B-12

Gear Shift Control Lever Rear Case 

Assembly Disassembly and Reassembly ....... 5B-13

Gear Shift Control Lever Rear Case 

Assembly Inspection ....................................... 5B-13

Gear Shift Lever Front Case Assembly 

Removal and Installation................................. 5B-14

Gear Shift Lever Front Case Assembly 

Disassembly and Reassembly........................ 5B-15

Gear Shift Lever Front Case Assembly 

Inspection........................................................ 5B-16

Engine Rear Mounting Replacement ................5B-16
Manual Transmission Assembly Dismounting 

and Remounting.............................................. 5B-16

Manual Transmission Unit Disassembly ........... 5B-18
Manual Transmission Unit Reassembly............5B-19
Locating Spring Inspection................................5B-23
Input Shaft Disassembly ...................................5B-23
Input Shaft Inspection ....................................... 5B-23
Input Shaft Reassembly.................................... 5B-25
Countershaft Disassembly and Assembly.........5B-27
Countershaft and Reverse Idle Gear 

Inspection........................................................ 5B-30

Output Shaft Disassembly and Assembly .........5B-31
Output Shaft Inspection .................................... 5B-31
Manual Transmission Front Case 

Disassembly and Assembly ............................5B-32

Manual Transmission Adapter Case 

Disassembly and Assembly ............................5B-32

Extension Case Assembly Components........... 5B-33
Extension Case Assembly Removal and 

Installation.......................................................5B-34

Extension Case Disassembly and 

Reassembly .................................................... 5B-34

Extension Case Assembly Inspection ...............5B-35

Specifications.....................................................5B-36

Tightening Torque Specifications......................5B-36

Special Tools and Equipment ...........................5B-36

Recommended Service Material....................... 5B-36
Special Tool ......................................................5B-37

For Diesel Engine Model ......................................5B-39

General Description ...........................................5B-39

Manual Transmission Construction...................5B-39

Diagnostic Information and Procedures..........5B-40

Manual Transmission Symptom Diagnosis ....... 5B-40

Repair Instructions ............................................5B-41

Manual Transmission Assembly Components ..5B-41

Gear Shift Lever Case Assembly 

Components....................................................5B-43

Gear Shift Shaft and Fork Components ............5B-44
Input Shaft Assembly, Main Shaft Assembly 

and Countershaft Assembly Components.......5B-45

Manual Transmission Oil Level Check..............5B-46
Manual Transmission Oil Change .....................5B-46
Transmission Shift Control Lever Removal 

and Installation ................................................5B-47

Transmission Shift Control Lever Inspection.....5B-48
Back Up Light Switch Removal and 

Installation .......................................................5B-48

Back Up Light Switch Inspection.......................5B-49
Gear Shift Lever Case Assembly Removal 

and Installation ................................................5B-49

Gear Shift Lever Case Assembly 

Disassembly and Reassembly ........................5B-50

Gear Shift Lever Case Assembly Inspection.....5B-51
Engine Rear Mounting Replacement ................5B-51
Manual Transmission Assembly Dismounting 

and Remounting..............................................5B-51

Manual Transmission Unit Disassembly ...........5B-53
Manual Transmission Unit Reassembly............5B-56
Locating Spring Inspection................................5B-60
Input Shaft Assembly Disassembly and 

Reassembly ....................................................5B-60

Input Shaft Inspection .......................................5B-60
Main Shaft Disassembly....................................5B-61
Main Shaft Inspection........................................5B-62
Main Shaft Reassembly ....................................5B-64
Countershaft Assembly Disassembly and 

Reassembly ....................................................5B-67

Reverse Idle Gear Assembly Disassembly 

and Reassembly .............................................5B-69

Countershaft and Reverse Idle Gear 

Inspection........................................................5B-70

Manual Transmission Adapter Case 

Disassembly and Assembly ............................5B-70

Specifications.....................................................5B-71

Tightening Torque Specifications......................5B-71

Special Tools and Equipment ...........................5B-71

Recommended Service Material .......................5B-71
Special Tool ......................................................5B-72

Clutch ....................................................... 5C-1

General Description .............................................5C-1

Clutch (Hydraulic Type) Construction .................5C-1

Component Location ...........................................5C-2

Clutch Fluid Pipe and Hose Location ..................5C-2

Diagnostic Information and Procedures............5C-3

Clutch (Hydraulic Type) Symptom Diagnosis......5C-3

Repair Instructions ..............................................5C-4

Clutch Pedal Height Inspection ...........................5C-4
Clutch Pedal Free Travel Check .........................5C-4
Clutch Fluid Inspection........................................5C-4
Air Bleeding of Clutch System.............................5C-4
Clutch Pedal Position (CPP) Switch Removal 

and Installation ..................................................5C-5