Suzuki Grand Vitara JB416 / JB420. Manual - part 240

5A-94 Automatic Transmission/Transaxle: 

7) Disconnect shift solenoid–A connector (1), shift 

solenoid–B connector (2), TCC pressure control 
solenoid connector (4) and Pressure control solenoid 
connector (3).

8) Remove solenoid valves.

9) After removing bolt (1) pull out transmission wire 

connector (2) from transmission case.

CAUTION

!

 

When pulling transmission wire harness out 
of transmission case, take care not to 
damage connectors and transmission fluid 
temperature sensor at narrow exist of case. 
Careless sensor treatment might cause 
sensor malfunction.

 

Installation
Remove removal procedure to install transmission fluid 
temperature sensor, noting the following points.
• For details of solenoid valves and their connectors 

installation, refer to “Automatic Transmission Unit 
Assembly”. Use new O-ring.

• For details of A/T oil pan installation, refer to 

“Automatic Transmission Unit Assembly”.

• Fill A/T fluid and check fluid level according to 

procedure described in “A/T Fluid Change”.

• Check for fluid leakage after warming up A/T.
• Tighten transmission wire connector bolt to specified 

torque referring to “Automatic Transmission Unit 
Assembly”.

Transmission Fluid Temperature Sensor 
Inspection

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Immerse transmission fluid temperature sensor (1) in 
water or oil. Check transmission fluid temperature 
sensor resistance between terminals of connector. Thus 
make sure its resistance decreases as temperature 
rises.
If sensor resistance is out of specification, replace 
solenoid wire harness (2).

Transmission fluid temperature sensor resistance
10 

°C (50 °F): 6.445 kΩ

25 

°C (77 °F): 3.5 kΩ

110 

°C (230 °F): 0.247 kΩ

3

4

1

2

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2

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4     3      2     1

8     7      6     5

2

1

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Automatic Transmission/Transaxle:  5A-95

Transmission Control Module (TCM) Removal 
and Installation

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CAUTION

!

 

TCM consists of highly precise parts, so 
when handling it, be careful not to expose it 
to excessive shock.

 

Removal

1) Disconnect negative cable at battery.
2) Disable air bag system.

Refer to “Disabling Air Bag System in Section 8B”.

3) Remove glove box.
4) Disconnect connectors from TCM (1).
5) Remove TCM with 4WD control module by removing 

its nuts, and then separate TCM and 4WD control 
module.

Installation
Reverse removal procedure noting the following points.
• Connect TCM connectors securely.
• Be sure to enable air bag system after TCM is back in 

place. Refer to “Enabling Air Bag System in Section 
8B”.

A/T Relay Inspection

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1) Disconnect negative cable at battery.
2) Remove integration relay No.2 (1) from fuse box 

No.2 (2).

3) Check that there is no continuity between terminals 

“E41-1” and “E38-8”.
If there is continuity, replace relay.

4) Connect battery positive (+) terminal to terminal 

“E38-6” of relay. Connect battery negative (–) 
terminal to terminal “E38-7” of relay. Check for 
continuity between terminal “E41-1” and “E38-8”. If 
there is no continuity when relay is connected to the 
battery, replace integration relay No.2.

1

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1

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1

1

2

3

4

5

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8

1

2

3

4

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6

7

8

E41

E41

E41

E37

E38

“E38-6”

“E41-1”

“E38-7”

“E38-8”

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5A-96 Automatic Transmission/Transaxle: 

Automatic Transmission Unit Components

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22

(b)

(b)

(c)

(c)

(c)

(c)

(d)

(e)

(e)

(e)

(f)

32

17

16

9

14

13

9

(c)

9

15

8

7

4

3

5

6

10

11

12

18

19

25

26

11

23

24

21

20

27

(f)

28

(f)

29

(a)

2

(a)

1

30

(b)

31

(b)

32

33

A

(a)

34

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Automatic Transmission/Transaxle:  5A-97

Automatic Transmission Assembly 
Dismounting and Remounting

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Dismounting

1) Dismount engine with transmission and transfer 

referring to “Engine Assembly Removal and 
Installation: For J20 Engine in Section 1D”.

2) Disconnect connectors from output shaft speed 

sensor, input shaft speed sensor, transmission range 
sensor, transmission wire, transfer actuator, 
differential lock switch and 4L/N switch release their 
wire harnesses from clamps.

3) Remove transfer from transmission.
4) Remove engine earth cable.
5) Remove engine rear mounting member and rear 

mounting.

6) Remove oil filler tube.
7) Remove cooler hose.
8) Remove drive plate cover, and then remove drive 

plate bolts by holding crankshaft pulley bolt 
stationary.

9) Remove Starting Motor referring to “Starting Motor 

Dismounting and Remounting in Section 1I”.

10) Remove transmission assembly from engine 

assembly.

Installation
For remounting, reverse dismounting procedure noting 
the following points.
• Tighten each bolts and nuts referring to “Automatic 

Transmission Unit Components”

• Tighten drive plate bolt No.1 (1) first and then tighten 

drive plate bolts No.2 (2).

• Set each clamp for wiring securely.
• Fill A/T fluid referring to “A/T Fluid Change”.
• Connect battery and check function of engine and 

transmission.

1. Torque converter mounting bolt No.1

: After tightening torque converter 
mounting bolt No.1, tighten torque 
converter mounting bolt No.2.

11. Transmission to engine bolt

21. Output shaft speed sensor

31. Engine earth cable bolt

2. Torque converter mounting bolt No.2

12. Exhaust pipe No.2 bracket bolt

22. Engine harness

32. Harness bracket bolt

3. Drive plate

13. Starting motor

23. Transfer

33. Harness bracket

4. Torque converter

14. Starting motor bolt

24. Transfer to transmission bolt

34. Drive plate bolt

5. Oil cooler hose

15. Transmission

25. Engine rear mounting

: 65 N

⋅m (6.5 kgf-m, 47.0 

lb-ft)

6. Clamp

16. Oil filler tube bolt

26. Engine rear mounting bolt

: 10 N

⋅m (1.0 kgf-m, 7.5 

lb-ft)

7. Drive plate cover bolt

17. Oil filler tube

27. Engine rear mounting bracket

: 80 N

⋅m (8.0 kgf-m, 58.0 

lb-ft)

8. Drive plate cover

18. Input shaft speed sensor

28. Engine rear mounting bracket 

bolt

: 50  N

⋅m (5.0 kgf-m, 36.5 

lb-ft)

9. Engine to transmission bolt

19. Output shaft speed sensor

29. Mounting member bolt

: 23 N

⋅m (2.3 kgf-m, 17.0 

lb-ft)

10. Exhaust pipe No.2 bracket

20. Transmission wire connector

30. Engine earth cable

: 55 N

⋅m (5.5 kgf-m, 40.0 

lb-ft)

1

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