Automatic Transmission: Removal & Installation Suzuki Aerio I

Select Cable Removal and Installation

Reference: Select CABLE COMPONENTS

Removal

1. Remove parking brake lever cover.
2. Remove console box.
3. Disconnect select cable from selector lever and then detach from bracket.
4. Remove clip and disconnect select cable from manual shift.
5. Remove select cable retainer from dash panel.

Installation

Reference: SELECT CABLE ADJUSTMENT

Install select cable by reversing removal procedure.

The important steps in installation are as follows.

1. Apply grease to pin and cable joint.
2. Tighten bolts to specified torque referring to «SELECT CABLE COMPONENTS»(ref-251085-S32901528942007032000000) .
3. Adjust selector cable referring to «SELECT CABLE ADJUSTMENT»(ref-251085-S32365053272007032000000) .

Scheme 102

Reference: OUTPUT SHAFT SPEED SENSOR INSPECTION

Scheme 103

1. Apply A/T fluid to new output shaft speed sensor O-ring.
2. Install output shaft speed sensor (1) to A/T case and tighten bolt to specified torque. Tightening torque Output shaft speed sensor bolt a: 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
3. Connect output shaft speed sensor connector (2) to output shaft speed sensor (1).
4. Connect negative cable to battery.

Reference: INPUT SHAFT SPEED SENSOR INSPECTION

Scheme 104

1. Apply A/T fluid to new input shaft speed sensor O-ring.
2. Install input shaft speed sensor (1) to A/T case and tighten bolt to specified torque. Tightening torque Input shaft speed sensor bolt a: 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
3. Connect input shaft speed sensor connector (2) to input shaft speed sensor (1).
4. Connect negative cable to battery.

Reference: TRANSMISSION FLUID TEMPERATURE SENSOR INSPECTION

Scheme 105

Scheme 106

1. Apply A/T fluid to new O-ring.
2. Install new O-ring to transmission fluid temperature sensor.
3. Install transmission fluid temperature sensor (1), and tighten A/T fluid temperature sensor to specified torque. Tightening torque Transmission fluid temperature sensor: 10 N.m (1.0 kg-m, 7.5 lb-ft)
4. Pour A/T fluid referring to «A/T FLUID CHANGE»(ref-251085-S41100126212007032000000) .
5. Connect transmission fluid temperature sensor connector (1).
6. Connect negative cable.
7. Verify that there is no A/T fluid leakage.

Reference: PRESSURE CONTROL SOLENOID VALVE INSPECTION

Reference: SOLENOID VALVES (SHIFT SOLENOID VALVES AND TCC SOLENOID VALVE) INSPECTION

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

1. Apply A/T fluid to new O-rings of solenoid valves and pressure control solenoid.
2. Install new O-rings to each solenoid valves and pressure control solenoid.
3. Install shift solenoid valve-A (No. 1) (1), shift solenoid valve-B (No. 2) (2) and TCC solenoid valve (3). Tightening torque Shift solenoid bolts a: 7.0 N.m (0.7 kg-m, 5.0 lb-ft)
4. Install pressure control solenoid (1). Tightening torque Pressure control solenoid bolt a: 7.0 N.m (0.7 kg-m, 5.0 lb-ft) Valve body bolt b: 10.0 N.m (1.0 kg-m, 7.5 lb-ft)
5. Connect solenoid connectors by identifying wire color. Solenoid coupler: Wire color Pressure control solenoid valve (1): Blue + Brown Shift solenoid valve-A (No. 1) (2): White Shift solenoid valve-B (No. 2) (3): Black TCC solenoid valve (4): Yellow
6. Clean mating surface transaxle case.
7. Apply sealant to mating surface of transaxle side cover and transaxle case by using a nozzle (1) as shown in figure by such amount that its section is 1.5 mm (0.059 in) in diameter. "A": Sealant 99000-31230
8. Install new transaxle side cover (1) by tightening new Torx® bolts to specified torque. Tightening torque Transaxle side cover bolts a: 13 N.m (1.3 kg-m, 9.40 lb-ft)
9. Pour A/T fluid referring to «A/T FLUID CHANGE»(ref-251085-S41100126212007032000000) .
10. Verify that there is no A/T fluid leakage.

Transmission Control Module (TCM) Removal and Installation

Scheme 112

1. Disconnect negative cable at battery.
2. If the vehicle is equipped with air bag system, disable air bag system. Refer to «DISABLING AIR BAG SYSTEM: ADVANCED AIR BAG»(ref-251097-S04938707892007032000000) or «DISABLING AIR BAG SYSTEM: EXCEPT ADVANCED AIR BAG»(ref-251097-S28088640732007032000000) .
3. Remove parking brake cover, console box (1) and console covers (2).
4. Disconnect connectors (3) from TCM (4).
5. Remove TCM (4) by removing its bolts (5).

Reverse removal procedure noting the following.

1. Connect TCM connectors securely.
2. If the vehicle is equipped with air bag system, be sure to enable air bag system after TCM is back in place. Refer to «ENABLING AIR BAG SYSTEM: ADVANCED AIR BAG»(ref-251097-S01682830192007032000000) «ENABLING AIR BAG SYSTEM: EXCEPT ADVANCED AIR BAG»(ref-251097-S15711231922007032000000) .

Scheme 113

1. Lift up vehicle and drain A/T fluid.
2. Remove drive shaft joints from differential gear of transaxle. Refer to «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION: FRONT»(ref-251075-S13290362612007032000000) for procedure to disconnect drive shaft joints. For differential side oil seal removal, it is not necessary to remove drive shafts from steering knuckle.
3. Remove differential side oil seal by using screw driver or the like.
4. Apply grease to new differential side oil seal lip. : Grease 99000-25030
5. Press-fit new differential side oil seal (1) until transaxle case end face (2) is flush with oil seal end, using special tool. Special Tool (A): 09924-07730
6. Install drive shaft referring to «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-251075-S13290362612007032000000) .
7. Pour A/T fluid referring to «A/T FLUID CHANGE»(ref-251085-S41100126212007032000000) .

Scheme 114

1. Remove parking brake cover and console box.
2. Replace shift lock solenoid (1).
3. Install covers as they were. NOTE: Check that detent pin (3) is locked at "P" position by lock plate (2). Check to confirm that lock plate (2) is pulled in when ignition key is turned to ON and brake pedal is depressed, so allowing detent pin (3) to be pushed down.

Key Interlock Cable Removal and Installation

Note. Don't bend interlock cable excessively when removing and installing it, or system will not operate correctly.

Scheme 115

Scheme 116

1. If the vehicle is equipped with air bag system, disconnect negative cable at battery and disable air bag system, referring to «DISABLING AIR BAG SYSTEM: ADVANCED AIR BAG»(ref-251097-S04938707892007032000000) or «DISABLING AIR BAG SYSTEM: EXCEPT ADVANCED AIR BAG»(ref-251097-S28088640732007032000000) .
2. Remove steering column cover.
3. Turn ignition switch to ACC position.
4. Pull out key interlock cable (1) from key cylinder cover (2) while pressing checkhook with slotted screwdriver (3) or the like.
5. Turn ignition switch to LOCK position.
6. Remove parking brake cover and console box.
7. Detach cable end (1) from interlock cam (2) while pressing claws (3) of interlock cam boss. At this time, be careful not to cause damage to its claws. Detach cable casing cap (4) from selector bracket (5) while pressing checkhook.
8. Remove interlock cable.

Scheme 117

Scheme 118

Scheme 119

1. Lay interlock cable to its original cabling route.
2. Turn ignition switch to ACC position.
3. Insert cable casing cap (1) into key cylinder cover (2) securely.
4. Pull out lock button (1) of selector side cable end (2).
5. Shift selector lever to "N" position. NOTE: If selector lever is in "P" position, shift selector lever referring to «SELECTOR LEVER INSPECTION»(ref-251085-S30201633962007032000000) .
6. Install cable casing cap (3) to selector bracket (4).
7. Connect cable end (1) to interlock cam (2) with ignition switch turned to ACC position.
8. Drive lock button (5) in cable end until it locks cable expansion and contraction.
9. With selector lever set at "P" position, turn ignition key to ACC position and then check for the following conditions. With knob button released, ignition key can be turned from ACC position to LOCK position. With knob button pressed, ignition key cannot be turned from ACC position to LOCK position.
10. Install steering column cover.
11. If the vehicle is equipped with air bag system, connect negative cable at battery and enable air bag system, referring to «ENABLING AIR BAG SYSTEM: ADVANCED AIR BAG»(ref-251097-S01682830192007032000000) «ENABLING AIR BAG SYSTEM: EXCEPT ADVANCED AIR BAG»(ref-251097-S15711231922007032000000) .

A/T Fluid Cooler Hoses Replacement

The rubber hoses for the A/T fluid cooler should be replaced at specified interval. When replacing them, be sure to note the following.

Scheme 120

1. to replace clamps at the same time
2. to insert hose as far as its limit mark
3. to clamp clamps securely

Scheme 121

Differential Gear Assembly Removal and Installation

Reference: AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

Reference: AUTOMATIC TRANSAXLE UNIT ASSEMBLY

Reference: DIFFERENTIAL COMPONENTS

Reference: DIFFERENTIAL PRELIMINARY CHECK

Scheme 122

1. Unclamp 4 final gear bolt lock plates (1).
2. Remove 8 bolts and 4 final gear bolt lock plates. NOTE: Don't reuse lock plates.
3. Remove final gear (2).

Scheme 123

Scheme 124

1. Install differential side right bearing race (1) and shim (2) to transaxle case (3), using special tool. Special Tool 09924-07710
2. Install differential side left bearing race (1) to transaxle housing (2), using special tool. Special Tool 09924-07710

Scheme 125

Scheme 126

Scheme 127

1. Heat final gear to about 100 °C (212 °F) in oil bath.
2. Clean mating surfaces of final gear and differential case.
3. Install final gear (1) to differential case (2).
4. Install new 4 final gear set bolt lock plates and 8 bolts and tighten bolts to specified torque. Tightening torque Final gear bolts a: 99 N.m (9.9 kg-m, 72.0 lb-ft)
5. Clamp bolts with lock plate (3) securely.
6. Install differential assembly to transaxle case and tighten case bolts to specified torque. Tightening torque Transaxle housing bolts: 30 N.m (3.0 kg-m, 22.0 lb-ft)
7. 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. Special Tool 09928-06020 Starting torque of differential assembly 0.7 - 1.2 N.m (0.07 - 0.12 kgf-m, 0.506 - 0.868 lb-ft) 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 128