2004 SUZUKI GRAND VITARA transfer oil 7a

YH4
GRAND
VITARA
Engine
Vehicle speed
sensor
Throttle position
sensor
ECT sensor
Cruise control
module
(if equipped)Torque converter Planetary gear
Final gear
reduction unit
Oil pump
Shift and TCC
solenoid valvesClutch and brake
Control valve
ªO / D OFFº lamp
ªPOWERº lamp
MILTransmission range
switch
O / D cut switch
P / N change switch
Transfer 4L switch
(if equipped)
CMP sensor Powertrain (engine) control module
Power transmission
Fluid pressure circuit
Electric signalInput speed sensor Brake pedal switch
Output speed sensor
AUTOMATIC TRANSMISSION (4 A / T) 7B1-7
ELECTRONIC SHIFT CONTROL SYSTEM
The gear ratio change in ªDº or ª2º range and torque converter clutch operation are controlled by Powertrain (En-
gine) Control Module.

YH4
GRAND
VITARA
7B1-74 AUTOMATIC TRANSMISSION (4 A / T)
1. Boot No.2
2. Boot cover
1. Boot clamp
2. Boot No.1
3. Gear shift control lever
1. Boot No.2
2. Transfer shift control
lever
3. Transfer shift lever case4. Transfer shift control
case cover
5. Boot No.1
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
G16 / J20 H25
DISMOUNTING OF TRANSMISSION (WITH
TRANSFER IF EQUIPPED)
IN CABIN
1) Remove console box.
NOTE:
To remove clip, push in its center pin first.
2) Remove boot cover and boot No.2. (if equipped)
3) Remove boot clamp and then remove boot No.1 from transfer
gear shift lever case. (if equipped)
4) With transfer shift control case cover pushed down with fingers,
turn it to counterclockwise and take out shift control lever. (if
equipped)
IN ENGINE ROOM
1) Remove battery, dipstick and oil filler tube.
2) Disconnect A
/
T throttle cable from throttle cam and bracket.
3) Remove starter motor. But don't disconnect its wiring harness.
4) Remove transmission to engine bolt and nut.

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

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.

YH4
GRAND
VITARA
7B1-78 AUTOMATIC TRANSMISSION (4 A / T)
ON-VEHICLE
SERVICE MOUNTING
EXTERNAL
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
Fastening portion
Tightening torque
Fastening portion
N´mkg-mlb-ft
Automatic transmission fluid drain plug232.317.0
Transfer oil filler / level and drain plugs232.317.0
Transmission case plug171.712.5
Manual select lever nut131.39.5
Manual select cable nut70.75.5
Manual selector assembly bolts181.813.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts
Engine rear mounting member bolts
Transmission case right stiffener bolts
505.036.5
Universal joint flange bolts and nuts505.036.5
Torque converter mounting bolts656.547.0
Adapter case or extension case bolts
(G16 engine)353.525.5
Adapter case or extension case bolts
(J20 / H25 engines)424.230.0
Transmission range switch lock bolt5.50.554.0
Oil pipe union bolts353.522.5
Drive plate bolts787.856.5
Interlock cable clamp screw2.20.221.5
Interlock cable outer mounting nut131.39.5

YH4
GRAND
VITARA
7D
TRANSFER 7D-1
The aluminum transfer case directly connected to the
back of the transmission contains the input gear,
countershaft & gear, output rear shaft, output low gear
and output front shaft (for front drive) connected by
way of the hyvo-chain.
The transfer has such a selective mechanism as to
enable the shift control lever to make selection of high
speed (direct connection with transmission output:
main shaft), low speed (speed reduction by input
gear, counter gear and output low gear) or neutral by
way of the reduction sleeve located between input
gear and output low gear, and selection of two-wheel-
drive (high speed only) or four-wheel-drive (high or
low speed) by way of the front drive clutch sleeve lo-cated at the center of the output rear shaft. Also, with
a synchronizer installed to the front drive clutch, it is
possible to change the drive mode between 2WD
(high speed only) and 4WD (high speed only) even
while running.
The front drive shift fork has an auxiliary spring to
make a smooth shift from 4H to 2H possible.
The case has an oil gutter and a plate at synchronizer
to provide proper lubrication even under the strict
conditions of use.
WARNING:
For towing the vehicle for the purpose of repair or
the like, follow the towing instructions in OWN-
ER'S MANUAL.
SECTION 7D
TRANSFER
CONTENTS
GENERAL DESCRIPTION7D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Oil7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Oil Seals7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Driven Gear7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Assembly7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remounting7D-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION

YH4
GRAND
VITARA
7D-2 TRANSFER
DIAGNOSIS
DIAGNOSIS TABLE
Before attempting to repair the transfer or related components for any reason other than mechanical failure, the
condition and probable causes should be identified.
Transfer failures are revealed by shifting difficulties such as excessive shifting effort, gear clash, or gear grinding.
When any of these conditions occur, the following inspections should be made before disassembling the transfer.
1) Check transfer oil level for insufficient or incorrect oil. Refer to ªTransfer and Differential Oil Inspection and
Changeº in SECTION 0B ªMAINTENANCE AND LUBRICATIONº.
2) Check transfer mountings for wear or looseness.
3) Check gearshift control lever for distortion or excessive wear.
After performing the above inspections, refer to following diagnosis table.
Condition
Possible CauseCorrection
Gear slipping out of mesh
Worn shift fork shaft

Worn shift fork or synchronizer sleeve

Weak or damaged locating spring

Worn bearings on output rear shaft

Worn chamfered tooth on sleeve or gear

Missing or disengagement of circlip(s)Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengage
Weakened or broken synchronizer spring

Distorted shift shaft or shift forkReplace
Replace
Hard shifting
Weakened front drive shift shaft spring

Distorted or mispositioned front drive shift
shaft circlip and washer

Inadequate or insufficient lubricant

Worn synchronizer ring

Worn chamfered tooth on sleeve or gear

Distorted shift shaftReplace
Replace
Replenish
Replace
Replace sleeve and gear
Replace
Noise
Inadequate or insufficient lubricant

Damaged or worn bearing(s)

Damaged or worn gear(s)

Damaged or worn synchronizer ring

Damaged or worn chamfered tooth on
sleeve or gearReplenish
Replace
Replace
Replace
Replace

YH4
GRAND
VITARA
1. Match mark
1. Transfer rear case
2. Oil seal
ªAº
ªBº
TRANSFER 7D-3
ON-VEHICLE SERVICE
GEAR OIL
Refer to ªON-VEHICLE SERVICEº of Section 7A or 7A1.
TRANSFER OIL SEALS
REAR CASE OIL SEAL
1) Lift up vehicle horizontally.
2) Give match marks on joint flange and propeller shaft as shown
in figure.
3) Remove 4 bolts from rear propeller shaft flange and remove pro-
peller shaft.
4) Using screwdriver, remove oil seal.
5) Using special tool(A) and plastic hammer, pressfit new oil seal
up to case surface. Be sure to apply grease to oil seal lip.
ªAº: Grease 99000-25010
Special Tool
(A): 09940-53111
6) 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
7) Install propeller shaft and torque universal joint flange bolts to
specification.
CAUTION:
Be sure to use only specified bolts, nuts and lock wash-
ers for universal joint flange.
Tightening Torque:
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
CENTER CASE OIL SEAL (Front side)
In addition to the procedure for rear case oil seal, it is necessary to
drain and refill gear oil of transfer. Refer to Section 7A ªON-VE-
HICLE SERVICEº for oil specification.