Removal & Installation - A/t: Other Suzuki Esteem I

GRAND VITARA & VITARA

Note. If vehicle is 2WD, disregard transfer case and 4WD component removal procedures in the following steps.

1. Disconnect negative battery cable. Remove transfer case shift lever knob. Remove console box. Remove retaining screws, shift lever boot and bracket.
2. Remove clamp and small boot located on top of transfer case at shift lever opening. Push downward on case cover (center area around shift lever) and rotate counterclockwise. Remove transfer case shift lever.
3. Disconnect T.V. cable at throttle body. Remove battery, transmission dipstick, filler tube, and starter without disconnecting harness. Support engine using appropriate engine support fixture.
4. Disconnect electrical connections, breather hose and control cables from transmission. Disconnect speedometer cable from transfer case. Disconnect and plug oil cooler lines from transmission. Remove gearshift assembly, if necessary.
5. Raise and support vehicle. Remove transfer case skid plate. Mark drive shaft flange and yokes for reassembly reference. Remove front and rear drive shafts.
6. Remove "E" ring and nut from end of gear select cable. Remove cable bracket. Remove exhaust pipe bracket at catalytic converter and transmission. Remove left case stiffener bracket. Disconnect oil cooler lines, and plug ends to prevent leakage. Loosen left case stiffener and remove bracket bolts from transmission.
7. Remove torque converter dust shield. Use Gear Stopper (09927-56010) to hold drive plate stationary, and remove torque converter-to-drive plate bolts. Support transmission with jack. DO NOT damage transmission oil pan.
8. Remove crossmember located below transmission and transfer case. Remove remaining transmission-to-engine bolts. Move transmission and transfer case away from engine. Disconnect wiring and hoses. Remove transmission from vehicle.

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Ensure reference marks are aligned on drive shaft flanges and yokes. Adjust all control cables. See ADJUSTMENTS in appropriate AUTOMATIC TRANSMISSION SERVICING article. Fill and check fluid levels.

SWIFT

Note. Engine and transaxle are removed as a unit.

1. Release fuel system pressure. Disconnect air intake tubing from air cleaner. Disconnect battery cables. Remove battery and tray. Disconnect ground cable at transaxle. Disconnect electrical connections, speedometer cable and control cables from engine and transaxle. Drain cooling system, and remove radiator and cooling fan as an assembly.
2. Remove starter. Raise and support vehicle. Drain engine and transaxle fluids. Disconnect and plug oil cooler lines from transaxle. Disconnect exhaust pipe from exhaust manifold.
3. Remove left axle shaft and disengage right axle shaft from differential. Remove left wheel. Remove staked area from left axle shaft nut at hub assembly. Remove nut and washer from left axle shaft.
4. Remove left ball joint-to-steering knuckle bolt. Separate ball joint from steering knuckle. Using 2 screwdrivers, pry axle shafts from transaxle case. Remove left axle shaft. Disconnect engine torque rod and bracket from transaxle. Lower vehicle and install engine hoist. Remove mounting nuts and bolts. Before removing engine and transaxle, ensure all hoses, wires and cables are disconnected. Lower engine and transaxle from engine compartment.
5. Support transaxle using a jack. Remove lower cover from torque converter housing. Disconnect transaxle mounts. Remove transaxle-to-engine bolts. Remove transaxle assembly. Remove drive plate-to-torque converter bolts. Drive plate can be held by engaging a screwdriver into drive plate gear through notch provided at underside of transaxle case.

1. To install transaxle, apply grease around cup at center of torque converter, and reverse removal procedure.
2. Ensure torque converter is correctly installed. Distance from torque converter drive lugs to engine mating surface of transaxle housing should be at least .84" (21.4 mm). If distance to mating surface is less than specified, torque converter has been installed improperly. Remove and reinstall torque converter correctly. Tighten drive plate bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8666-S06415318422000091200000) . Remount transaxle to engine. Install engine and transaxle into vehicle.
3. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-8666-S06415318422000091200000) . Install all hoses and wires. Adjust all cables. See ADJUSTMENTS in appropriate AUTOMATIC TRANSMISSION SERVICING article. Fill and check coolant, engine and transaxle fluid levels.