1999 SUZUKI GRAND VITARA front
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YH4
GRAND
VITARA
MANUAL TRANSMISSION (TYPE 1) 7A-13
1
1. Extension case
2. Select return spring bolt
3. Select return spring (short)
4. Select return spring (long)
5. Guide pin
6. Speed sensor assembly 62,ªAº,(a)
3,ªAº
5,ªAº
5,ªAº
4,ªAº
2,ªAº,(a)
1. Oil seal
2. Extension case
ªBºªAº
1
1
22
EXTENSION CASE (2WD MODEL)
DISASSEMBLY
1) Remove oil seal.
2) Remove select return spring bolts and then springs and guide
pins.
3) Remove speed sensor assembly.
REASSEMBLY
1) Install oil seal.
2) After applying grease, install select guide pins, select return
springs and spring bolts and torque them to specification.
ªAº: Grease 99000-25010
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
After installing, check to make sure that each pin moves smooth-
ly.
3) Install speedometer driven gear case assembly to extension
case.
EXTENSION CASE OIL SEAL (2WD MODEL)
REMOVAL AND INSTALLATION
1) Remove propeller shaft referring to SECTION 4B.
2) Using screwdriver, remove oil seal.
3) Using special tool (A) and plastic hammer, press fit new oil seal
into extension case till oil seal contacts stepped part of extension
case as shown. Be sure to apply grease to oil seal lip.
ªAº: Grease 99000-25010
Special Tool
(A): 09951-16060
4) Clean and inspect sliding portion of propeller shaft front end
(where oil seal contacts) before installation and if even small
dent or scratch exists, correct and clean it again.
Then apply grease inside splines of propeller shaft.
ªBº: Grease 99000-25010
5) Install propeller shaft referring to SECTION 4B.
Page 405 of 801
YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-3
1. Torque converter
2. Overdrive input shaft
3. Oil pump
4. Overdrive brake
5. Overdrive clutch
6. Forward clutch input shaft
7. Forward clutch
8. Direct clutch
9. One-way clutch
10. Second coast brake
11. Second brake
12. Reverse brake
13. Front planetary gear
14. Rear planetary gear
15. Overdrive planetary gear
GENERAL DESCRIPTION
This automatic transmission is a full automatic type with 3-speed plus overdrive (O / D).
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled
lock-up mechanism. The gear shift device consists of 3 sets of planetary gear units, 3 disc type clutches, 4 disc
type brakes and 3 one-way clutches. The gear shift is done by selecting one of 6 positions (ªPº, ªRº, ªNº, ªDº, ª2º
and ªLº) by means of the select lever installed on the floor. On the shift knob, there is an overdrive (O / D) cut switch
which allows shift-up to the overdrive mode (except at 4L) and shift-down from the overdrive mode. Also, by using
the P / N change switch located on the console box, it is possible to select the gear change timing of 2 modes, nor-
mal and power.
Page 407 of 801
YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-5
1. Overdrive clutch
2. Overdrive brake
3. Forward clutch
4. Direct clutch
5. Second coast brake
6. Second brake
7. Reverse brake
8. One-way clutch No.2
9. One-way clutch No.1
10. Overdrive one-way clutch
11. Overdrive input shaft
12. Forward clutch input shaft
13. Intermediate shaft
CLUTCH / BRAKE FUNCTIONS
Part NameFunction
Overdrive clutchMeshes overdrive carrier and overdrive sun gear.
Overdrive brakeFixes overdrive sun gear.
Overdrive one-way clutchMeshes overdrive carrier and overdrive sun gear only when driven
by engine.
Forward clutchMeshes input shaft and intermediate shaft.
Direct clutchMeshes input shaft with front sun gear and rear sun gear.
Second coast brakeFixes front sun gear and rear sun gear.
Second brakeFixes outer race of one-way clutch No.1, to prevent front sun gear
and rear sun gear from turning counterclockwise (reverse direction
of engine input rotation direction).
Reverse brakeFixes front planetary carrier.
One-way clutch No.1Prevents front sun gear and rear sun gear from turning counterclockwise
only when second brake is at work.
One-way clutch No.2Prevents front planetary carrier from turning counterclockwise.
Page 459 of 801
YH4
GRAND
VITARA
1
1. Shift solenoids connector
AUTOMATIC TRANSMISSION (4 A / T) 7B1-57
MANUAL ROAD TEST
This test check the gear being used in ªLº, ª2º or ªDº range when
driven with unoperated gear shift control system. Test drive vehicle
on a level road.
NOTE:
Before this test, check diagnostic trouble code (DTC).
1) Disconnect coupler of shift solenoid valves on transmission.
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when disconnecting shift solenoid
valves coupler.
2) With select lever in ªPº, start engine and warm it up.
3) With select lever in ªLº range, start vehicle and accelerate to 20
km/h (12.5 mile/h). Check in this state that 1st gear is being
used.
4) At 20 km/h (12.5 mile/h), shift select lever to 2 range and acceler-
ate to 40 km/h (25 mile/h). Check in this state that 3rd gear is
being used.
5) At 40 km/h (25 mile/h), shift select lever to D range and check
that O/D gear is used when speed is higher than 40 km/h (25
mile/h).
6) After above checks, stop vehicle then engine, and connect shift
solenoids coupler with ignition switch OFF.
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when connecting shift solenoid valves
coupler.
7) Clear DTC with scan tool.
TIME LAG TEST
This test is to check conditions of clutch, reverse brake and fluid
pressure. ªTime lagº means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels re-
spectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from ªNº to ªDº range
and measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from ªNº to ªRº
range.
Specification for ªNºªDºLess than 1.2 sec.
time lagªNºªRºLess than 1.5 sec.
NOTE:
When repeating this test, be sure to wait at least minute
after select lever is shifted back to ªNº range.
Engine should be warmed up fully for this test.
Test resultPossible causes
When ªNºªDº time lag
exceeds specificationLow line pressure
Worn forward clutch
When ªNºªRº time lag
exceeds specificationLow line pressure
Worn direct clutch
Worn reverse brake
Page 467 of 801
YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-65
1. Drain plug
2. Propeller shaft
1. Oiler (with transmission fluid)
2. Solenoid valve
3. BatteryA: Hole (Should be dry)
B: Exhausting fluid Terminal Arrangement of PCM Coupler
(Viewed from harness side)
WITH BATTERY VOLTAGE WITHOUT BATTERY VOLTAGE
H25 Engine
Shift solenoid valve ± A (#1)C51-1-6
Shift solenoid valve ± B (#2)C51-1-1
TCC (Lock-up) solenoid valveC51-1-2
REMOVAL
1) Pull out dipstick and lift up vehicle.
2) With engine cooled, remove drain plug from oil pan and drain
A / T fluid.
3) Install drain plug with gasket.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Remove exhaust pipe bracket and disconnect front propeller
shaft from front differential (if equipped).
5) Remove oil pan bolts.
6) Remove oil pan.
7) Remove oil tubes.
8) Remove solenoid valve No.1 (shift solenoid valve A and B) or so-
lenoid valve No.2 (TCC solenoid valve).
OPERATION CHECK
Whenever shift solenoid valves and TCC (lock-up) solenoid valve
are removed from transmission, verify their valve function physical-
ly before they are reinstalled.
1) Apply oiler to solenoid valve and give compression by hands
and then check to be sure that transmission fluid from oiler does
not come out of holes in solenoid valve when battery voltage is
not conducted.
2) Under the same conditions as above, conduct battery voltage
and then make sure that fluid comes out with vigor.
NOTE:
If fluid does not come out with vigor in above step 2 in-
spection, do not re-use that solenoid valve.
Figure at the left shows shift solenoid valve check.
Check TCC solenoid valve also in the same way.
Page 477 of 801
YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-75
1. Drain plug
2. Filler and level plug
1. Drain plug
2. Front propeller shaft
1. Match marks
1. Right side transmission stiffener (if equipped)
G16 / J20
ON LIFT
1) Drain transfer oil for 4WD vehicle or A / T fluid for 2WD vehicle.
NOTE:
If 4WD automatic transmission is overhauled later on,
draining A / T fluid at this point will facilitate work.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
2) Before removing propeller shaft, give match marks on joint
flange and propeller shaft as shown in left figure.
3) Remove universal joint flange bolts and take out rear propeller
shaft.
4) Likewise, take out front propeller shaft. (if equipped)
5) Remove nut from the end of select cable and bracket to set
cable free.
6) Remove select cable bracket by removing its 2 bolts.
7) Remove exhaust No.1 and No.2 pipe.
8) Remove transmission stiffener (right side) if equipped.
9) Unclamp and disconnect oil cooler hoses from pipes.
NOTE:
To avoid leakage of transmission fluid, plug open ends of
oil cooler pipes and hoses right after they are discon-
nected.
10) Remove torque converter housing lower plate.
11) Holding drive plate stationary with special tool or the like, re-
move torque converter mounting bolts with wrench.
Special Tool (only for G16 / J20)
(A): 09927-56010
Page 479 of 801
YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-77
ªAº, (d)
1. Drive plate
2. Torque converter
3. Case right stiffener (if equipped)
4. Automatic transmissionTightening torque
(a): 50 N´m
5.0 kg-m
36.5 lb-ft
(b): 65 N´m
6.5 kg-m
47.0 lb-ft
(c): 85 N´m
8.5 kg-m
61.5 lb-ft
(d): 78 N´m
7.8 kg-m
56.5 lb-ft
1. Automatic transmission
2. Transfer (4WD)
3. Engine rear mounting
4. Engine rear mounting member Tightening torque
(a): 50 N´m (5.0 kg-m, 36.5 lb-ft) ªAº: Sealant 99000-31110
REMOUNTING
WARNING:
When moving transmission assembly with torque convert-
er equipped in it, be sure to keep it horizontal. Tilting it with
its front facing down may allow converter to fall off. Where-
by an injury may result.
For remounting, reverse dismounting procedure. Use specified
torque as given below and left.
Tightening torque
N.mkg-mlb-ft
Exhaust No.1 pipe to manifold
bolts or nuts505.036.5
Muffler to exhaust No.2 pipe
nuts606.043.5
Universal joint flange bolts and
nuts505.036.5
Oil filler tube bolts
Select cable bracket bolts232.317.0
Clamp wiring harness and hoses securely.
Refer to ªSelect Cableº section for adjusting procedure of select
cable.
Refer to ªA / T Throttle Cableº section for tuning of A / T throttle
cable.
Follow fluid level check procedure for refilling automatic transmis-
sion fluid and its level adjusting.
Connect battery, and confirm that engine and transmission func-
tion acceptably.
When remounting drive plate, use specified bolts.
Page 484 of 801
YH4
GRAND
VITARA
CLUTCH 7C1-3
DIAGNOSIS
ConditionPossible CauseCorrection
SlippingImproper clutch pedal free travel.
Worn or oily clutch disc facing.
Warped disc, pressure plate or flywheel
surface.
Weakened diaphragm spring.
Master cylinder piston or seal cup not returning.Bleed air or replace master
cylinder.
Replace disc.
Replace disc, clutch cover or
flywheel.
Replace clutch cover.
Repair master cylinder.
Dragging clutchImproper clutch pedal free travel.
Weakened diaphragm spring, or worn spring tip.
Rusted input shaft splines.
Damaged or worn splines of transmission
input shaft.
Excessively wobbly clutch disc.
Clutch facings broken or dirty with oil.
Fluid leakage.Bleed air or replace master
cylinder.
Replace clutch cover.
Lubricate.
Replace input shaft.
Replace disc.
Replace disc.
Repair or replace.
Clutch vibrationGlazed (glass-like) clutch facings.
Clutch facings dirty with oil.
Release bearing slides unsmoothly on input
shaft bearing retainer.
Wobbly clutch disc, or poor facing contact.
Weakened torsion springs in clutch disc.
Clutch disc rivets loose.
Distorted pressure plate or flywheel surface.
Weakened or loosened engine mounting
bolt or nut.Repair or replace disc.
Replace disc.
Lubricate or replace input
shaft bearing retainer.
Replace disc.
Replace disc.
Replace disc.
Replace clutch cover or flywheel.
Retighten or replace mounting.
Noisy clutchWorn or broken release bearing.
Input shaft front bearing worn down.
Excessive rattle of clutch disc hub.
Cracked clutch disc.
Pressure plate and diaphragm spring rattling.Replace release bearing.
Replace input shaft bearing.
Replace disc.
Replace disc.
Replace clutch cover.
Grabbing clutchClutch disc facings soaked with oil.
Clutch disc facings excessively worn.
Rivet heads showing out of facing.
Weakened torsion springs.Replace disc.
Replace disc.
Replace disc.
Replace disc.