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Automatic Transmission: Removal & Installation Suzuki Forenza I

Automatic Trans 36 illustrations ~2112 words

Installation

  1. Install the shift control cable into the fire wall of the vehicle.
  2. Install the shift control cable onto the transaxle mount.
  3. Install the shift control cable onto the shift control assembly.
  4. Install the shift control cable adjuster pinch nut. Tighten: Tighten the shift control cable adjuster pinch nut to 8 N.m (71 lb-in).
  5. Install the clip to the shift control cable at the transaxle mount connection.
  6. Install the clip to the select lever connection on the transaxle case.
  7. Adjust the shift control cable. Refer to «Shift Control Cable Adjustment»(ref-257093-S24757124022007062900000) .
  8. Connect the negative battery cable.
  1. Install the TCM into the bracket.
  2. Connect the wiring connectors.
  3. Connect the negative battery cable.

Scheme 22

Scheme 22: Removal
Scheme 22: Removal

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Disconnect the negative battery cable.
  2. Disconnect the park/neutral position switch electrical connector.
  3. Disconnect the shift control cable and the retaining clip.
  4. Remove the shift lever nut and the shift lever.
  5. Remove the park/neutral start switch.

Tools Required

DW260-050 Park/Neutral Switch Installer

Scheme 25

Scheme 25: Installation
Scheme 25: Installation

Scheme 26

Scheme 26
Scheme 26
  1. Install the park/neutral start switch. Tighten: Tighten the park/neutral start switch bolts to 10 N.m (89 lb-in).
  2. Adjust the park/neutral switch using the Park/Neutral switch installer DW260-050.
  3. Install the shift lever and the shift lever nut. Tighten: Tighten the shift lever nut to 10 N.m (89 lb-in).
  4. Connect the shift control cable and the retaining clip.
  5. Connect the park/neutral position switch electrical connector.
  6. Connect the negative battery cable.

Removal

CAUTIONPlace a drip pan under the hoses to catch the fluid that will run out of the lines.

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29
  1. Disconnect the negative battery cable.
  2. Raise and suitably support the vehicle.
  3. Remove the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
  4. Remove the oil cooler outlet pipe bolt from the right lower side of the radiator.
  5. Remove the oil cooler outlet pipe bracket bolt.
  6. Remove the oil cooler outlet pipe bolt from the transaxle side.
  7. Remove the oil cooler outlet pipe assembly.
  8. Remove the oil cooler inlet pipe bolt from the left lower side of the radiator.
  9. Remove the oil cooler inlet pipe bolt from the transaxle side.
  10. Remove the oil cooler inlet pipe assembly.

Scheme 30

Scheme 30: Installation
Scheme 30: Installation

Scheme 31

Scheme 31
Scheme 31
  1. Install the oil cooler inlet pipe assembly and the bolts. Tighten: Tighten the oil cooler inlet pipe bolts to 35 N.m (26 lb-ft).
  2. Install the oil cooler outlet pipe assembly and the bolts. Tighten: Tighten the oil cooler outlet pipe bolts to 35 N.m (26 lb-ft).
  3. Refill the transaxle fluid. Refer to «Transaxle Fluid Level Checking Procedure»(ref-257093-S35556437662007062900000) .
  4. Install the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
  5. Connect the negative battery cable.

Scheme 32

Scheme 32: Removal
Scheme 32: Removal
  1. Disconnect the negative battery cable.
  2. Remove the drive axles. Refer to «DRIVE AXLE ASSEMBLY REMOVAL AND INSTALLATION»(ref-257085-S12318101822007062900000) .
  3. Remove the transaxle drive seal using a screwdriver. If necessary, crush the seal first with the screwdriver in order to loosen the seal from the case.

Tools Required

DW260-030-01 Axle Seal Installer (LH)

DW260-030-02 Axle Seal Installer (RH)

Scheme 33

Scheme 33: Installation
Scheme 33: Installation
  1. Install the transaxle drive seal using the axle seal installer DW260-030-01 (LH) or DW260-030-02 (RH).
  2. Install the drive axles. Refer to «DRIVE AXLE ASSEMBLY REMOVAL AND INSTALLATION»(ref-257085-S12318101822007062900000) .
  3. Connect the negative battery cable.

Oil Pan, Oil Pan Gasket Removal and Installation

Tools Required

DW260-070 Plug Remover/Installer

Scheme 34

Scheme 34
Scheme 34
  1. Disconnect the negative battery cable.
  2. Raise and suitably support the vehicle.
  3. Remove the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
  4. Place a fluid container below the fluid drain plug.
  5. Remove the transaxle fluid drain plug using the plug remover/installer DW260-070 and drain the transaxle fluid.
  6. Remove the oil cooler inlet and outlet pipes. Refer to «Oil Cooler Pipes/Hoses Removal and Installation»(ref-257093-S17889428772007062900000) .
  7. Remove the oil pan and oil pan gasket.
  1. Install the oil pan, oil pan gasket and bolts. Tighten: Tighten the oil pan bolts to 6 N.m (53 lb-in).
  2. Install the oil cooler inlet and outlet pipes. Refer to «Oil Cooler Pipes/Hoses Removal and Installation»(ref-257093-S17889428772007062900000) .
  3. Install the transaxle fluid drain plug using the plug remove/installer DW260-070.
  4. Install the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
  5. Refill the transaxle fluid. Refer to «Transaxle Fluid Level Checking Procedure»(ref-257093-S35556437662007062900000) .
  6. Connect the negative battery cable.

Control Valve Body Assembly Removal and Installation

Tools Required

DW260-070 Plug Remover/Installer

Scheme 35

Scheme 35: Removal
Scheme 35: Removal

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38
  1. Disconnect the negative battery cable.
  2. Disconnect the transaxle wiring harness and the park/neutral position switch electrical connector.
  3. Raise and suitably support the vehicle.
  4. Remove the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
  5. Remove the transaxle fluid drain plug using the plug remover/installer DW260-070 and drain the transaxle fluid.
  6. Remove the oil pan, oil pan gasket. Refer to «Oil Pan, Oil Pan Gasket Removal and Installation»(ref-257093-S16814124912007062900000) .
  7. Remove the valve body mounting bolts.
  8. Remove the automatic transaxle input speed sensor mounting bolt.
  9. Tilt the valve body.
  10. Remove the automatic transaxle output speed sensor mounting bolt under the valve body assembly.
  11. Remove the control valve body.
  1. Tilt the valve body.
  2. Install the output speed sensor mounting bolt. Tighten: Tighten the output speed sensor mounting bolt to 6 N.m (53 lb-in).
  3. Install the control valve body and the bolts. Tighten: Tighten the valve body mounting bolts to 8 N.m (71 lb-in).
  4. Install the input speed sensor mounting bolt. Tighten: Tighten the input speed sensor mounting bolt to 8 N.m (71 lb-in).
  5. Install the oil pan and oil pan gasket. Refer to «Oil Pan, Oil Pan Gasket Removal and Installation»(ref-257093-S16814124912007062900000) .
  6. Install the transaxle fluid drain plug using the plug remove/installer DW260-070.
  7. Install the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
  8. Lower the vehicle.
  9. Connect the transaxle wiring harness and the PNP switch electrical connector.
  10. Refill the transaxle fluid. Refer to «Transaxle Fluid Level Checking Procedure»(ref-257093-S35556437662007062900000) .
  11. Connect the negative battery cable.

Left Transaxle Mounting Bracket Removal and Installation

Tools Required

DW110-060 Engine Support Fixture

Scheme 39

Scheme 39: Removal
Scheme 39: Removal

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41
  1. Remove the battery. Refer to «BATTERY AND BATTERY TRAY REMOVAL AND INSTALLATION»(ref-257078-S26914448212007062900000) .
  2. Install the engine support fixture DW110-060.
  3. Remove the left transaxle mounting bolts.
  4. Remove the left transaxle mount bracket cage bolts and nut.
  5. Remove the transaxle mounting bracket.
  1. Install the left transaxle mount bracket cage bolts and nut. Tighten: Tighten the left transaxle mount bracket cage bolt (a) to 110 N.m (81 lb-ft). Tighten the left transaxle mount bracket cage bolt (b) to 65 N.m (48 lb-ft). Tighten the left transaxle mount bracket cage nut (c) to 65 N.m (48 lb-ft).
  2. Install the left transaxle mounting bolts to 48 N.m (35 lb-ft).
  3. Remove the engine support fixture DW110-060.
  4. Install the battery. Refer to «BATTERY AND BATTERY TRAY REMOVAL AND INSTALLATION»(ref-257078-S26914448212007062900000) .

Tools Required

DW110-060 Engine Support Fixture

DW260-010 Transaxle Support Fixture

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47
  1. Disconnect the negative battery cable.
  2. Position the select lever park position.
  3. Remove the battery. Refer to «BATTERY AND BATTERY TRAY REMOVAL AND INSTALLATION»(ref-257078-S26914448212007062900000) .
  4. Install the engine support fixture DW110-060.
  5. Disconnect the transaxle wiring harness from the transaxle.
  6. Disconnect the park/neutral position switch electrical connector.
  7. Remove the clips from the shift control cable and disconnect the shift control cable from the transaxle.
  8. Remove the upper transaxle-to-engine bolts.
  9. Remove the left transaxle mounting bracket. Refer to «Left Transaxle Mounting Bracket Removal and Installation»(ref-257093-S32361392762007062900000) .
  10. Raise and suitably support the vehicle.
  11. Drain the transaxle fluid.
  12. Remove the oil cooler pipes from the transaxle. Refer to «Oil Cooler Pipes/Hoses Removal and Installation»(ref-257093-S17889428772007062900000) .
  13. Remove the drive axle. Refer to «DRIVE AXLE ASSEMBLY REMOVAL AND INSTALLATION»(ref-257085-S12318101822007062900000) .
  14. Remove the starter motor. Refer to «DIAGNOSTIC AIDS»(ref-257067-S39495042132007062900000) .
  15. Remove the torque converter bolts.
  16. Support the transaxle.
  17. Remove the rear transaxle mounting bracket bolts (a) and damping block connection bolt and nut (b).
  18. Support the transaxle assembly using the transaxle support fixture DW260-010.
  19. Remove the lower engine-to-transaxle bolts.
  20. Remove the transaxle assembly.

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49
  1. Install the transaxle into the vehicle.
  2. Support the transaxle assembly using the transaxle support fixture DW260-010.
  3. Install the lower engine-to-transaxle bolts. Tighten: Tighten the lower engine-to-transaxle bolts (a) to 75 N.m (55 lb-ft). Tighten the lower engine-to-transaxle bolt (b) to 21 N.m (15 lb-ft). Tighten the lower engine-to-transaxle bolt (c) to 31 N.m (23 lb-ft).
  4. Install the rear transaxle mounting bracket bolts (a). Tighten: Tighten the rear transaxle mounting bracket bolts (a) to 62 N.m (45 lb-ft).
  5. Install the damping block connection bolt and nut (b). Tighten: Tighten the damping block connection bolt and nut (b) to 68 N.m (50 lb-ft).
  6. Install the torque converter bolts.
  7. Install the starter motor. Refer to «DIAGNOSTIC AIDS»(ref-257067-S39495042132007062900000) .
  8. Install the drive axle. Refer to «DRIVE AXLE ASSEMBLY REMOVAL AND INSTALLATION»(ref-257085-S12318101822007062900000) .
  9. Install the oil cooler pipes from the transaxle. Refer to «Oil Cooler Pipes/Hoses Removal and Installation»(ref-257093-S17889428772007062900000) .
  10. Lower the vehicle.
  11. Install the left transaxle mounting bracket. Refer to «Left Transaxle Mounting Bracket Removal and Installation»(ref-257093-S32361392762007062900000) .
  12. Install the upper transaxle-to-engine bolts. Tighten: Tighten the upper transaxle-to-engine bolts to 75 N.m (55 lb-ft).
  13. Install the clips to the shift control cable and connect the shift cable.
  14. Install the park/neutral position switch electrical connector.
  15. Connect the transaxle wiring harness to the transaxle.
  16. Remove the engine support fixture DW110-060.
  17. Install the battery. Refer to «BATTERY AND BATTERY TRAY REMOVAL AND INSTALLATION»(ref-257078-S26914448212007062900000) .
  18. Add the transaxle fluid. Refer to «Transaxle Fluid Level Checking Procedure»(ref-257093-S35556437662007062900000) .
  19. Connect the negative battery cable.

Scheme 50

Scheme 50: Disassembly and Assembly
Scheme 50: Disassembly and Assembly
  1. Remove the transaxle assembly. Refer to «Transaxle Assembly Removal and Installation»(ref-257093-S24456154242007062900000) .
  2. Remove the torque converter assembly.
  3. Installation should follow the removal procedure in the reverse order.

Measuring Installation Space, Clutch B (EB)

Tools Required

DW260-090 Clutch B/E (installation space) Measuring Fixture

DW260-120 Clutch B Adjust Ring

DW260-130 Clutch E Adjust Ring

  1. First of all, remove B clutch set, snap ring and C clutch set.
  2. Install DW260-130, snap ring and DW260-120.
  3. Put the dial gauge sensor on Clutch B Adjust Ring DW260-120.
  4. Feed compressed air to Clutch E Adjust Ring DW260-130 via DW260-090 (C2 position).
  5. Set the dial gauge on DW260-120's upper surface to zero.
  6. Lift DW260-120 by hand until it touches the cup and read the measurement value.
  7. Repeat measurement twice with the set turned by 120°.
  8. Average measurement values M1, M2, M3. (measurement value is MB) The minimum installation space EB is equal to the height of DW260-120 (RB) plus measurement value MB CALCULATION MB = (M1 + M2 + M3) / 3 EB = RB + MB EXAMPLE M1 = 2.36 mm M2 = 2.40 mm M3 = 2.38 mm So, MB = (2.36 + 2.40 + 2.38) / 3 = 2.38 mm After measuring the ring height of DW260-120, if the value (RB) is 11.99 mm, EB = 11.99 + 2.38 =14.37 mm

Measuring Installation Space, Clutch E (EE)

Tools Required

DW260-090 Clutch B/E (snap ring play, installation space) Measuring Fixture

DW260-120 Clutch B Adjust Ring

DW260-130 Clutch E Adjust Ring

  1. Install DW260-130, snap ring and DW260-120.
  2. Put the dial gauge sensor on Clutch E Adjust Ring DW260-130.
  3. Feed compressed air to Clutch B Adjust Ring DW260-120 via DW260-090 (C1 position).
  4. Set the dial gauge on DW260-130's upper surface to zero.
  5. Lift DW260-130 by hand until it touches the snap ring's bottom surface and read the measurement value.
  6. Repeat measurement twice with the set turned by 120°.
  7. Average measurement values M4, M5, M6. (measurement value is ME) The minimum installation space EE is equals ring height of DW260-130 (RE) plus measurement value ME. CALCULATION ME = (M4 + M5 + M6) / 3 EE = RE + ME EXAMPLE M4 = 2.4 mm M5 = 2.35 mm M6 = 2.34 mm So, ME = (2.4 + 2.35 + 2.34) / 3 = 2.36 mm After measuring the ring height of DW260-130, if the value (RE) is 20.98 mm, EE = 20.98 + 2.36 = 23.34 mm

Brake F, Slotted Nut Disassembly and Assembly and Installation

Tools Required

DW260-060 Brake F Split Stop Ring Remover

Scheme 51

Scheme 51: Brake F, Slotted Nut Disassembly and Assembly and Installation
Scheme 51: Brake F, Slotted Nut Disassembly and Assembly and Installation

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54
Scheme 54

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56
  1. Remove the side shaft. Refer to «Side Shaft Disassembly and Assembly»(ref-257093-S29009161582007062900000) .
  2. Take OFF the disc set and the brake F inner disc carrier.
  3. Mount fixture and remove the brake F split stop ring.
  4. Remove the fixture and take off the cup spring.
  5. Release the piston F by applying compressed air to the bore.
  6. Remove piston F and bearing plate with spur gear.
  7. Installation should follow the removal procedure in the reverse order.

Measuring Installation Space F

Tools Required

DW260-110 Brake F Disc Clearance Measuring Bar

Scheme 57

Scheme 57: Measuring Installation Space F
Scheme 57: Measuring Installation Space F
  1. Using a depth gauge, measuring from the transaxle housing sealing surfaces to the piston's disc support surface at two opposing points = M1, M2
  2. Average the measurement values M1, M2 = BF CALCULATION BF = (M1 + M2) / 2 EXAMPLE M1 = 18.6 mm M2 = 18.8 mm BF = 18.7 mm

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