Automatic Transmission: Other Suzuki Aerio I

General Service Procedure Information

When repairing automatic transaxle, it is necessary to conduct the on-vehicle test to investigate where the cause of the trouble lies first.

Then whether overhaul should be done or not is determined. If the transaxle is disassembled without such preliminary procedure, not only the cause of the trouble would be unknown, but also a secondary trouble may occur and often time would be wasted.

Functions

FUNCTIONS CHART

Shift Lock Solenoid Control

This system consists of shift lock solenoid control system and interlock cable control system.

The shift lock solenoid control system is so designed that the select lever can not be shifted from "P" range position unless ignition switch is turned to "ON" or "ACC" position and the brake pedal is depressed.

And interlock cable control system is so designed that select lever cannot be shifted from "P" range position unless ignition switch is turned to "ACC" or "ON" position. Also, ignition key cannot be pulled out of key slot unless select lever is in "P" range.

Shift Lock Solenoid Manual Release

Without using brake pedal, shift lock plate be moved by pushing shift lock solenoid release button with flat end rod (2) or like through hole (1). (To shift select lever from "P" range to any other position, turn ignition switch to ACC or ON position.)

Scheme 295

2 Driving Cycle Detection Logic

When a malfunction is detected during initial driving cycle, TCM transmits a data to inform ECM of malfunction occurrence. At this time, ECM stores a corresponding pending DTC in its memory. (but MIL does not light). If the same malfunction is also detected in next driving cycle, ECM lights MIL when it receives a data informing occurrence of a malfunction from TCM.

Freeze Frame Data

Refer to ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION .

Scheme 296

Automatic Gear Shift Table (for 2WD Model)

Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D position.

1. Shift Point in D position

AUTOMATIC GEAR SHIFT CHART (2WD MODEL)

2. Lock-up point in D position

LOCK-UP POINT IN D POSITION

Automatic Gear Shift Table (for 4WD Model)

Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D position and normal mode.

AUTOMATIC GEAR SHIFT (4WD MODEL)

LOCK-UP POINT IN D POSITION CHART

Scheme 297

Bearing and race dimensions

BEARING AND RACE DIMENSIONS CHART

Scheme 298

A/T System Check

Refer to the following items for the details of each step.

DIAGNOSIS PROCEDURE

Step 1. Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer.

For this purpose, use of such an inspection form as shown in the following page as an example will facilitate collecting information to the point required for proper analysis and diagnosis.

Scheme 299

Note. The form is a standard sample. It should be modified according to conditions characteristic of each market.

Step 10. Check for Intermittent Problem

Check parts where an intermittent trouble is easy to occur (e.g. wire harness, connector, etc.), referring to INTERMITTENT AND POOR CONNECTION INSPECTION and related circuit of DTC recorded in Step 2.

Malfunction Indicator Lamp (MIL) Check

Refer to the same item in MALFUNCTION INDICATOR LAMP (MIL) CHECK for checking procedure.

Scheme 300

"O/D OFF" Lamp Check

1. Turn ignition switch ON.
2. Check that "O/D OFF" lamp (1) lights for about 2 sec. and then goes OFF.

If anything faulty is found, advance to "O/D OFF" Lamp Circuit Check .

Scheme 301

Fail Safe Table

This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The following table shows the fail safe function for each fail condition of sensor, solenoid, TCM or its circuit.

FAIL SAFE CHART

Gear position (P/N or R/1/2/3/4)

Current gear position computed by throttle position coming from ECM and vehicle speed.

Engine speed (RPM)

Engine speed computed by reference pulses from crankshaft position sensor.

Input shaft rev (Input shaft revolution, RPM)

Input shaft revolution computed by reference pulses coming from input shaft speed sensor on transaxle case.

Output shaft rev (Output shaft revolution, RPM)

Output shaft revolution computed by reference pulses coming from output shaft speed sensor on transaxle case.

Battery volt. (Battery voltage, V)

Battery voltage read by TCM as analog input signal by TCM.

ATF temp. (ATF temperature, °C, °F)

ATF temperature decided by signal from transmission fluid temperature sensor installed in valve body.

Shift sol #1 COM/MON (Shift solenoid-A (No. 1) command/monitor, ON/OFF)

COM-ON: ON command being outputted to shift solenoid-A (No. 1)

COM-OFF: ON command not being outputted to shift solenoid-A (No. 1)

MON-ON: Electricity being passed to shift solenoid-A (No. 1)

MON-OFF: Electricity not being passed to shift solenoid-A (No. 1)

Shift sol #2 COM/MON (Shift solenoid-B (No. 2) command/monitor, ON/OFF)

COM-ON: ON command being outputted to shift solenoid-B (No. 2)

COM-OFF: ON command not being outputted to shift solenoid-B (No. 2)

MON-ON: Electricity being passed to shift solenoid-B (No. 2)

MON-OFF: Electricity not being passed to shift solenoid-B (No. 2)

TCC sol COM/MON (TCC solenoid command/monitor, ON/OFF)

COM-ON: ON command being outputted to TCC solenoid

COM-OFF: ON command not being outputted to TCC solenoid

MON-ON: Electricity being passed to TCC solenoid

MON-OFF: Electricity not being passed to TCC solenoid

Press cont sol (Pressure control solenoid, %)

Electric current value ratio between electric current value being outputted from TCM to solenoid and maximum value can be outputted by TCM.

Vehicle speed (kph / mph)

Vehicle speed computed by reference pulses coming from vehicle speed sensor on transaxle case.

O/D off switch (ON / OFF)

Inputted signal from O/D off switch on selector knob.

ON: O/D off switch ON

OFF: O/D off switch OFF

Trans. range (P/R/N/D/2/L)

Transaxle range detected by signal fed from transmission range sensor.

D range signal (P/N range / D range)

Transaxle range detected by signal fed from transmission range sensor.

Throttle position (Throttle position, %)

Throttle opening ratio computed by duty signal from ECM.

Brake switch (ON / OFF)

Inputted signal from brake light switch on pedal bracket.

ON: Brake pedal depressed

OFF: Brake pedal released

Coolant temp. (°C, °F)

Engine coolant temperature computed by duty signal from ECM.

A/C switch

ON: Signal which inform that air conditioner compressor is turned ON .

OFF: Signal which inform that air conditioner compressor is not turned ON .

Cruise control sw

ON: Signal which inform that lock-up inhibit signal from cruise control module is turned ON .

OFF: Signal which inform that lock-up inhibit signal from cruise control module is turned OFF .

A/T Basic Check

This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in visual inspection. Follow the flow table carefully.

DTC CHART

Electrical repair

A/T SYMPTOM DIAGNOSIS PROCEDURE 1

On-vehicle repair

A/T SYMPTOM DIAGNOSIS PROCEDURE 2

Off-vehicle repair

A/T SYMPTOM DIAGNOSIS PROCEDURE 3

No Gear Shift to O/D

System Description

TCM does not shift to O/D gear under any of the following condition.

1. O/D off switch is turned ON. ("O/D OFF" lamp ON.)
2. O/D off signal by cruise control module is ON.
3. TCC solenoid circuit is in faulty condition and transmission fluid temperature is more than 150 °C (302 °F). (P2763 / P2764)

1. Reference waveform No. 1

Output shaft speed sensor signal (1) and input shaft speed sensor signal (2) at 64 km/h (40 mph)

WAVEFORM REFERENCE 1 CHART

Scheme 302

2. Reference waveform No. 2

Throttle opening signal (from ECM)

WAVEFORM REFERENCE 2 CHART

Scheme 303

3. Reference waveform No. 3

Engine coolant temp. signal (from ECM)

WAVEFORM REFERENCE 3 CHART

Scheme 304

4. Reference waveform No. 4

Serial data line to speedometer

WAVEFORM REFERENCE 4 CHART

Scheme 305

5. Reference waveform No. 5

Engine speed signal from ECM

WAVEFORM REFERENCE 5 CHART

Scheme 306

6. Reference waveform No. 6

Engine torque reduction signal

WAVEFORM REFERENCE 6 CHART

Scheme 307

7. Reference waveform No. 7

Engine torque signal from ECM

WAVEFORM REFERENCE 7 CHART

Scheme 308

8. Reference waveform No. 8

Serial communication line from ECM

WAVEFORM REFERENCE 8 CHART

Scheme 309

9. Reference waveform No. 9

Pressure control solenoid valve output signal

WAVEFORM REFERENCE 9 CHART

Scheme 310

Scheme 311

Resistance Check

Shift solenoid valve-A (No. 1), -B (No. 2) and TCC solenoid valve

Shift solenoid valve-A and B resistance

Standard: 11 - 15 ohms at 20 °C (68 °F)

TCC solenoid valve resistance

Standard: 12 - 16 ohms at 20 °C (68 °F)

Scheme 312

Check resistance between pressure control solenoid valve (1) terminals. If check result is not as specified, replace solenoid valve.

Pressure control solenoid valve resistance

Standard: 5.0 - 5.6 ohms (at 20 °C (68 °F))

Scheme 313

Not using regulated DC power supply

1. Connect pressure control solenoid valve (1) to battery (2) setting the 8 - 10 W bulb (4) on the way as shown in the figure.
2. Check for movement of valve (3) in the direction of arrow "A".
3. Disconnect pressure control solenoid valve (1) from battery (2) and check movement of valve (3) in the direction of arrow "B" as shown in the figure. CAUTION: Set 8 - 10 W bulb on the way, or pressure control solenoid valve is burned out.

Scheme 314

Automatic Transaxle Unit Dismounting and Remounting

Reference: AUTOMATIC TRANSAXLE UNIT COMPONENTS

Scheme 315

Scheme 316

Scheme 317

Scheme 318

1. Take down transaxle with engine. For its procedure, refer to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
2. Remove engine rear mounting No. 1 bracket and engine rear mounting No. 2 bracket with stiffener (for 2WD vehicle).
3. Remove transfer referring to «TRANSFER DISMOUNTING AND REMOUNTING»(ref-251077-S24392748132007032000000) (for 4WD vehicle).
4. Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from differential side gear (for 2WD vehicle).
5. Remove lower stiffener (1).
6. Remove torque converter bolts. To lock drive plate (1), engage a flat head rod or the like (2) with drive plate gear.
7. Remove starting motor.
8. Remove bolts and nut fastening engine and transaxle, then detach transaxle from engine. NOTE: When detaching transaxle from engine, move it in parallel with crankshaft and use care so as not to apply excessive force to drive plate and torque converter. WARNING: Be sure to keep transaxle with torque converter horizontal or facing up throughout the work. Should it be tilted with torque converter down, converter may fall off and cause personal injury.

Scheme 319

Scheme 320

Scheme 321

Scheme 322

1. Make sure that torque converter is installed correctly to transaxle. Refer to «AUTOMATIC TRANSAXLE UNIT ASSEMBLY»(ref-251085-S17181239062007032000000) .
2. Attach transaxle to engine. Tightening torque Transaxle to engine bolts and nut a: 85 N.m (8.5 kg-m, 61.5 lb-ft) WARNING: Be sure to keep transaxle with torque converter horizontal or facing up throughout the work. Should it be tilted with torque converter down, converter may fall off and cause personal injury.
3. Tighten drive plate-torque converter bolts. Align drive plate bolt hole and torque converter through then tighten bolts through torque converter housing lower plate opening. Lock drive plate (1) by engaging a flat head rod or the like (2) with drive plate gear. Tightening torque Drive plate to torque converter bolts a: 25 N.m (2.5 kg-m, 18.1 lb-ft)
4. Install lower stiffener. Tighten transaxle stiffener bolts (a) first and next (b) with specified torque. Tightening torque Lower stiffener bolts: 50 N.m (5.0 kg-m, 36.5 lb-ft)
5. Install starter motor. Tightening torque Starter motor bolts: 50 N.m (5.0 kg-m, 36.5 lb-ft)
6. Install center shaft (1) to differential gear (for 2WD vehicle). Tighten center bearing support bolts to specified torque. CAUTION: Be careful not to scratch oil seal lip with center shaft while inserting. Tightening torque Center bearing support bolts a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
7. Install engine rear mounting brackets and stiffener (for 2WD vehicle).
8. Install transfer referring to «TRANSFER DISMOUNTING AND REMOUNTING»(ref-251077-S24392748132007032000000) (for 4WD vehicle).
9. Remount engine with transaxle assembly to vehicle. Refer to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) for its procedure.

Scheme 323

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Scheme 325

2nd Coast Brake and 2nd Brake Preliminary Check

Reference: AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

Reference: AUTOMATIC TRANSAXLE UNIT ASSEMBLY

Scheme 326

Scheme 327

1. Measure 2nd brake piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm 2 , 57 - 113 psi) through oil hole (1) by using special tools. If measured piston stroke exceeds specified value, disassemble and inspect inner parts. Special Tool 09900-20607 09900-20701 2nd brake piston stroke Standard: 1.91 - 2.69 mm (0.075 - 0.106 in.)
2. Measure 2nd coast brake piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm 2 , 57 - 113 psi) through oil hole (1) by using special tools. If measured piston stroke exceeds specified valve, disassemble and inspect inner parts. Special Tool 09900-20607 09900-20701 2nd coast brake piston stroke Standard: 0.82 - 1.66 mm (0.032 - 0.156 in.)

Forward and Direct Clutch Preliminary Check

Reference: AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

Reference: AUTOMATIC TRANSAXLE UNIT ASSEMBLY

Scheme 328

Scheme 329

1. Install forward and direct clutch assembly (1) to transaxle rear cover (2).
2. Measure forward clutch piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm 2 , 57 - 113 psi) through oil hole (3) by using special tools. If measured piston stroke exceeds specified value, disassemble and inspect inner parts. Special Tool 09900-20607 09900-20701 Forward clutch piston stroke Standard: 1.52 - 1.89 mm (0.059 - 0.074 in.)
3. Measure direct clutch piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm 2 , 57 - 113 psi) through oil hole (1) by using special tools. If measured piston stroke exceeds specified value, disassemble and inspect inner parts. Special Tool 09900-20607 09900-20701 Direct clutch piston stroke Standard: 1.52 - 1.89 mm (0.059 - 0.074 in.)

Underdrive Clutch and One-Way No. 3 Clutch Preliminary Check

Reference: AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

Reference: AUTOMATIC TRANSAXLE UNIT ASSEMBLY

Scheme 330

1. Install underdrive clutch (1) to transaxle case (2).
2. Measure underdrive clutch piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kg/cm 2 , 57 - 113 psi) through oil hole (4) by using special tools. If measured piston stroke exceeds specified value, disassemble and inspect inner parts. Special Tool 09900-20607 09900-20701 Underdrive clutch piston stroke Standard: 1.22 - 1.69 mm (0.048 - 0.067 in.)

Planetary Front Gear

Measure inside diameter of planetary front gear (1) bushing, using special tools. If inside diameter exceeds limit, replace planetary front gear.

Planetary front gear bushing inside diameter limit

30.13 mm (1.186 in.)

Special Tool

1. 09900-20607
2. 09900-22403

Note. Perform measurement at several points.

Scheme 331

Planetary Sun Gear

Measure inside diameter of planetary sun gear (1) bushing, using special tools. If inside diameter exceeds limit, replace planetary sun gear.

Planetary sun gear bushing inside diameter limit

21.58 mm (0.849 in.)

Special Tool

1. 09900-20607
2. 09900-22403

Note. Perform measurement at several points.

Scheme 332

Scheme 333

Underdrive Gear Preliminary Check

Reference: AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

Reference: AUTOMATIC TRANSAXLE UNIT ASSEMBLY

Measure starting torque of underdrive gear, using spring force gauge, attach cord at gear of underdrive gear. If starting torque is out of specification, replace underdrive gear assembly.

Starting torque of underdrive gear

0.55 - 1.35 N.m (0.06 - 0.14 kgf-m, 0.40 - 1.01 lb-ft)

Scheme 334

Scheme 335

Differential Preliminary Check

Reference: AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

Reference: AUTOMATIC TRANSAXLE UNIT ASSEMBLY

Scheme 336

1. Install differential assembly (1) to transaxle case and tighten case bolts to specified torque. Tightening torque Transaxle housing bolts: 30 N.m (3.0 kg-m, 22 lb-ft)
2. Measure differential assembly starting torque, using special tool. If starting torque exceeds specified value, replace shim in the following so as starting torque to be in standard value. Starting torque of differential assembly 0.7 - 1.2 N.m (0.07 - 0.12 kgf-m, 0.506 - 0.868 lb-ft) Special Tool 09928-06020 Available differential side bearing shim thickness (Thickness: Identification) BEARING SHIM THICKNESS SPECIFICATIONS 1.00 mm (0.039 in.): 21 1.48 mm (0.058 in.): 33 1.05 mm (0.041 in.): 22 1.51 mm (0.059 in.): 34 1.10 mm (0.043 in.): 23 1.54 mm (0.060 in.): 35 1.15 mm (0.045 in.): 24 1.57 mm (0.061 in.): 36 1.20 mm (0.047 in.): 25 1.60 mm (0.062 in.): 37 1.25 mm (0.049 in.): 26 1.65 mm (0.064 in.): 38 1.30 mm (0.051 in.): 27 1.70 mm (0.066 in.): 39 1.33 mm (0.052 in.): 28 1.75 mm (0.068 in.): 40 1.36 mm (0.053 in.): 29 1.80 mm (0.070 in.): 41 1.39 mm (0.054 in.): 30 1.85 mm (0.072 in.): 42 1.42 mm (0.055 in.): 31 1.90 mm (0.074 in.): 43 1.45 mm (0.057 in.): 32

Scheme 337

1. Hold differential assembly with soft jawed vice and set special tools as shown. Special Tool 09900-20607 09900-20701
2. Measure differential gear thrust play. If thrust play exceeds specified value, replace differential assembly. Differential gear thrust play Standard: 0.05 - 0.20 mm (0.0024 - 0.0087 in.)

Recommended Service Material

RECOMMENDED SERVICE MATERIAL CHART