Suzuki Grand Vitara JB416 / JB420. Manual - part 242

5A-102 Automatic Transmission/Transaxle: 

33) Remove manual shift shaft and lever as follows.

a) Undo caulking of sleeve cover (1) by using flat 

end rod or the like and hammer.

b) Drive out manual shift lever pin (1) by using 

special tool and hammer.

Special tool
(A):  09922–89810 

c) Pull out manual shift shaft (2) from transmission 

case, and then remove manual shift lever (3) and 
sleeve cover (4).

34) Remove oil seal (1) from both sides of transmission 

case.

35) Remove cover plate (1).

1

I4JA01512082-01

1

3

(A)

2

4

I4JA01512083-01

IYSQ01510111-01

1

I5JB0A510089-01

Automatic Transmission/Transaxle:  5A-103

Oil Pump Components

S5JB0A5106068

4

6

FLD

2

1

FLD

3

5

(a)

I5JB0A510090-01

1. Oil pump body oil seal

4. Seal ring

: 7.5 N

⋅m (0.75 kgf-m, 5.5 lb-ft)

2. Oil pump cover O-ring

5. Oil pump body

: Do not reuse.

3. Oil pump cover

6. Oil pump bolt

: Apply A/T fluid.

5A-104 Automatic Transmission/Transaxle: 

Oil Pump Disassembly and Assembly

S5JB0A5106069

Disassembly

1) Remove 6 bolts, oil pump cover (1), drive gear and 

driven gear in that order.

2) Remove oil pump cover O-ring.
3) Remove oil pump body oil seal (1) using special tool.

Special tool
(A):  09913–50121 

Assembly
Assemble each component by reversing removal 
procedure and noting the following points.
• Before installing inner gear and outer gear to pump 

body, apply A/T fluid to them.

• Install oil pump seal using special tool.

Special tool
(A):  09913–85210 

• When installing pump cover, use care so that its 

splined part will not cause damage to oil seal and use 
specified torque to tighten it to pump body.

Tightening torque
Oil pump bolt (a):  7.5 N·m (0.75 kgf-m, 5.5 lb-ft)

• When installing O-ring and oil seal, apply enough A/T 

fluid to them and fit them securely in groove.

• After installation, check that inner gear turns smoothly 

by making use of torque converter.

• When installing seal ring, it should not be opened 

more than necessary.

• Fit claws of seal ring securely.

Oil Pump Inspection

S5JB0A5106070

• Check seal ring (2) and bushing (1) for wear and 

damage.

• Check clearance between outer gear (1) and body.

Clearance between outer gear and body
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
Service limit: 0.30 mm (0.0118 in.)

1

I5JB0A510091-01

1

(A)

I5JB0A510093-01

(A)

I5JB0A510092-01

IYSQ01510114-01

1

2

I5JB0A510094-01

IYSQ01510116-01

Automatic Transmission/Transaxle:  5A-105

• Check tip clearance between inner gear (1) and outer 

gear.

Tip clearance between inner gear and outer gear
Standard: 0.11 – 0.14 mm (0.0043 – 0.0055 in.)
Service limit: 0.30 mm (0.0118 in.)

NOTE
Measure with torque converter installed.

 

• Check side clearance between inner gear/outer gear 

and pump body.

Side clearance between inner gear / outer gear 
and pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.0020 in.)
Service limit: 0.1 mm (0.0039 in.)

• Measure inside diameter of oil pump body bushing.

If inside diameter exceeds limit, replace oil pump 
body.

Oil pump body bushing inside diameter standard
38.113 – 38.138 mm (1.5005 – 1.5014 in.)

• Measure inside diameter of stator shaft assembly 

bushing.
If inside diameter exceeds limit, replace stator shaft 
assembly.

Stator shaft assembly bushing inside diameter 
standard
Front side (2): 21.501 – 21.527 mm (0.8465 – 0.8475 
in.)
Rear side (1): 23.025 – 23.051 mm (0.9065 – 0.9075 
in.)

IYSQ01510117-01

IYSQ01510118-01

I4JA01512140-01

I5JB0A510148-01