Suzuki Grand Vitara JB627. Manual - part 239

5A-140 Automatic Transmission/Transaxle: 

22) Install brake plate stopper spring (1) to transmission 

case.

23) Install one-way No.3 clutch assembly (1) including 

one-way No.3 clutch inner race (2) to transmission 
case.

24) Install snap ring (1) by using special tool being sure 

not to align snap ring end gap with cut portion of 
transmission case.

Special tool
(A):  09900–06108

25) Install thrust bearing race No.4 (3) to middle 

planetary gear assembly (1).

26) Install middle planetary gear assembly (1) including 

planetary sun gear (2) into intermediate shaft.

27) After applying A/T fluid to new 2 O-rings (1) and then 

install O-rings to No.2 brake piston (2).

28) Install No.2 brake piston (2) to No.2 brake cylinder 

(3).

CAUTION

!

 

Do not twist or deviate O-ring during 
installation.

 

29) Install No.2 brake cylinder (2) including No.2 brake 

piston (1) to transmission case.

1

I4JA01512232-01

1

2

I4JA01512233-01

1

(A)

I4JA01512234-01

3

2

1

I4JA01512235-01

1

2

3

I4JA01512236-01

1

2

I4JA01512237-01

Automatic Transmission/Transaxle:  5A-141

30) Install No.2 brake piston return spring (1) with spring 

side of plate facing to No.2 brake disc side.

31) Install No.2 brake discs “D” and No.2 brake plates 

“P” in the following order.
P - D - P - D - P - D

32) Install No.2 brake flange “F” with spring flange side 

of flange facing to No.2 brake disc side.

33) Compress No.2 brake piston return spring until the 

No.2 brake flange is lowered to the place 1 – 2 mm 
(0.039 – 0.078 in.) from the snap ring groove by 
using special tool.

CAUTION

!

 

Be careful when applying pressure, for 
overpressure will cause No.2 brake return 
spring to deform.

 

Special tool
(A):  09927–66510
(B):  09913–85210
(C):  09920–13120

34) Place snap ring on No.2 brake flange being sure not 

to align snap ring end gap with cut portion 
transmission case.

35) After applying A/T fluid to new 2 O-rings (1) and then 

install O-rings to No.1 brake piston (2).

36) Install No.1 brake piston (2) to No.1 brake cylinder 

(3).

CAUTION

!

 

Do not twist or deviate O-ring during 
installation.

 

37) Install No.1 brake cylinder (2) including No.1 brake 

piston (1) to transmission case.

38) Place No.1 brake piston return spring (3) on No.1 

brake piston (1).

1

F

P

D

I4JA01512238-01

(A)

(B)

(C)

I4JA01512354-01

1

2

3

I4JA01512240-01

1

3

2

I4JA01512241-01

5A-142 Automatic Transmission/Transaxle: 

39) Compress No.1 brake piston return spring until the 

No.1 brake piston return spring is lowered to the 
place 1 – 2 mm (0.039 – 0.078 in.) from the snap ring 
groove by using special tool.

CAUTION

!

 

Be careful when applying pressure, for 
overpressure will cause plate section of No.1 
brake piston return spring to deform.

 

Special tool
(A):  09927–66530
(B):  09913–85210
(C):  09920–13120

40) Place snap ring on No.1 brake piston being sure not 

to align snap ring end gap with cut portion 
transmission case.

41) Install middle planetary ring gear (1) and front 

planetary ring gear flange (2) onto front planetary 
ring gear.

42) Install snap ring (1) by using flat end rod or the like.

43) After applying petroleum jelly to thrust needle roller 

bearing (1) so that thrust needle roller bearing does 
not fall off.

44) Install front planetary ring gear (2) and thrust needle 

roller bearing (1) into intermediate shaft.

45) Install thrust needle roller bearing (1) and thrust 

bearing race No.3 (2) onto front planetary ring gear.

(A)

(B)

(C)

I4JA01512355-01

2

1

I4JA01512243-01

1

I4JA01512244-01

2

1

I4JA01512245-01

2

1

I4JA01512246-01

Automatic Transmission/Transaxle:  5A-143

46) Fit planetary carrier thrust washer No.2 (1) to front 

planetary gear assembly (2) with petroleum jelly so 
that planetary carrier thrust washer No.2 (1) does not 
fall off.

NOTE
Make sure projection part of planetary carrier 
thrust washer No.2 fit into holes of front 
planetary gear assembly.

 

47) Install front planetary gear assembly (2) and one-

way No.1 clutch inner race (3) onto front planetary 
ring gear.

NOTE
Make sure align front planetary gear 
assembly trenches (4) and one-way No.1 
clutch inner race holes (5).

 

48) Install No.1 brake discs “D”, No.1 brake plates “P” 

and No.1 brake flange “F” in the following order.
P - D - P - D - P - D - F

49) Using vernier calipers, measure the level difference 

(length A) between the upper surface of the No.1 
brake piston and the hitting surface of No.1 brake 
flange at the both end across a diameter, and 
calculate the average.

NOTE

• No.1 brake piston must be installed tightly 

to the end face of transmission case.

• Length A:

15.29 – 15.77 mm (0.602 – 0.628 in.)

 

3

2

1

5

4

I4JA01512247-01

F

P

D

I4JA01512248-01

A

I4JA01512356-01