Automatic Transmission: Removal & Installation Suzuki Verona I

Shift Control Lever Assembly Installation

1. Install the bolts and the shift control assembly. Tighten: Tighten the bolts to 8 N.m (71 lb-in.).
2. Install the shift control cable onto the bracket and tighten the nut.
3. Install the shift control cable adjuster pinch nut. Tighten: Tighten the shift control cable adjuster pinch nut to 8 N.m (71 lb-in.).
4. Connect the electrical switch connectors.
5. Install the floor console. Refer to «FLOOR CONSOLE INSTALLATION»(ref-257324-S32070685422007070900000) .
6. Connect the negative battery cable.

Scheme 22

1. Disconnect the negative battery cable.
2. Remove the air filter housing assembly and bolts.
3. Remove the clip from the selector lever connection on the transaxle case and disconnect the shift control cable from the selector lever connection.
4. Remove the clip from the shift control cable at the transaxle mount connection.
5. Remove the floor console. Refer to «FLOOR CONSOLE REMOVAL»(ref-257324-S00043136172007070900000) .
6. Loosen the shift control cable adjuster pinch nut.
7. Loosen the nut from the cable bracket.
8. Remove the shift control cable from the shift control assembly.
9. Remove the shift control cable from the transaxle mount.
10. Pull the shift control cable through the fire wall of the vehicle, bringing the rubber grommet with it.

Scheme 23

Shift Control Cable 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. Tighten the nut on the cable bracket.
5. Install the shift control cable adjuster pinch nut. Tighten: Tighten the nut to 8 N.m (71 lb-in.).
6. Install the clip to the shift control cable at the transaxle mount connection.
7. Install the clip to the select lever connection on the transaxle case.
8. Adjust the shift control cable. Refer to «Shift Control Cable Adjustment»(ref-257306-S24952554212007070900000) .
9. Install the air filter housing assembly and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb-in.).
10. Connect the negative battery cable.

Transaxle Control Module (TCM) Installation

1. Install the TCM and nuts. Tighten: Tighten the TCM mounting nuts to 23 N.m (17 lb-ft).
2. Connect the wiring connectors.
3. Connect the negative battery cable.

Scheme 24

Scheme 25

1. Disconnect the negative battery cable.
2. Remove the air filter housing.
3. Disconnect the Park/Neutral position switch electrical connector.
4. Disconnect the shift control cable and the retaining clip.
5. Remove the shift lever nut and the shift lever.
6. Remove the Park/Neutral start switch.

Scheme 26

Park/neutral Start Switch Installation

Tools Required

DW260-050 Park/Neutral Position Switch Installer

Scheme 27

Scheme 28

1. Install the Park/Neutral start switch. Tighten: Tighten the bolts to 10 N.m (89 lb-in.).
2. Adjust the Park/Neutral switch using the Park/Neutral switch installer DW260-050. CAUTION: When install the Park/Neutral switch, using the special service tools and the shift lever must be positioned "Neutral".
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. Install the air filter housing.
7. Connect the negative battery cable.

Oil Cooler Pipes / Hoses Removal

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the oil cooler outlet pipe bolt from the right lower side of the radiator.
4. Remove the oil cooler outlet pipe bracket bolt.
5. Remove the oil cooler outlet pipe bolt from the transaxle side.
6. Remove the oil cooler outlet pipe assembly.
7. Remove the oil cooler inlet pipe bolt from the left lower side of the radiator.
8. Remove the oil cooler inlet pipe bolt from the transaxle side.
9. Remove the oil cooler inlet pipe assembly.

Scheme 33

Scheme 34

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 «Changing the Fluid»(ref-257306-S38151395012007070900000) .
4. Connect the negative battery cable.

Scheme 35

1. Disconnect the negative battery cable.
2. Remove the drive axles. Refer to «DRIVE AXLE ASSEMBLY REMOVAL»(ref-257299-S10203536352007070900000) . CAUTION: Be careful not to damage the bore of the transaxle case.
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.

Drive Axle Oil Seal Installation

Tools Required

DW260-030-01 Axle Seal Installer (LH)

DW260-030-02 Axle Seal Installer (RH)

Scheme 36

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 INSTALLATION»(ref-257299-S20501949482007070900000) .
3. Connect the negative battery cable.

Oil Pan and Oil Pan Gasket Removal

Tools Required

DW260-070 Plug Remover/Installer

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»(ref-257278-S07126482362007070900000) .
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»(ref-257306-S30046725732007070900000) .
7. Remove the oil pan and oil pan gasket.

Scheme 37

Oil Pan and Oil Pan Gasket Installation

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 Installation»(ref-257306-S06153017712007070900000) .
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 INSTALLATION»(ref-257278-S39530346152007070900000) .
5. Refill the transaxle fluid. Refer to «Changing the Fluid»(ref-257306-S38151395012007070900000) .
6. Connect the negative battery cable.

Control Valve Body Assembly Removal

Tools Required

DW260-070 Plug Remover/Installer

Scheme 38

Scheme 39

Scheme 40

1. Disconnect the negative battery cable.
2. Remove the air filter housing.
3. Disconnect the transaxle wiring harness and the Park/Neutral position switch electrical connector.
4. Raise and suitably support the vehicle.
5. Remove the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL»(ref-257278-S07126482362007070900000) .
6. Remove the transaxle fluid drain plug using the plug remover/installer DW260-070 and drain the transaxle fluid.
7. Remove the oil pan, oil pan gasket. Refer to «Oil Pan and Oil Pan Gasket Removal»(ref-257306-S25724851372007070900000) .
8. Remove the valve body mounting bolts.
9. Remove the automatic transaxle input speed sensor mounting bolt.
10. Tilt the valve body.
11. Remove the automatic transaxle output speed sensor mounting bolt under the valve body assembly.
12. Remove the control valve body.

Control Valve Body Assembly Installation

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 and Oil Pan Gasket Installation»(ref-257306-S30273897112007070900000) .
6. Install the transaxle fluid drain plug using the plug remover/installer DW260-070.
7. Install the engine under cover. Refer to «ENGINE UNDER COVERS INSTALLATION»(ref-257278-S39530346152007070900000) .
8. Lower the vehicle.
9. Connect the transaxle wiring harness and the PNP switch electrical connector.
10. Install the air filter housing.
11. Refill the transaxle fluid. Refer to «Changing the Fluid»(ref-257306-S38151395012007070900000) .
12. Connect the negative battery cable.

Left Transaxle Mounting Bracket Removal

Tools Required

DW110-060 Engine Support Fixture

Scheme 41

Scheme 42

1. Remove the air filter housing.
2. Install the engine support fixture DW110-060.
3. Remove the 4 transaxle mounting bolts.
4. Remove the bolt and nut from the transaxle mounting bracket cage.

Left Transaxle Mounting Bracket Installation

1. Install the left 4 transaxle mounting bracket bolts. Tighten: Tighten the left 4 transaxle mounting bracket bolts to 40 N.m (30 lb-ft).
2. Install the bolt and nut to the left transaxle mounting bracket cage. Tighten: Tighten the bolt and nut to 65 N.m (48 lb-ft).
3. Remove the engine support fixture DW110-060.
4. Install the air filter housing.

Transaxle Assembly Removal

Tools Required

DW110-060 Engine Support Fixture

DW260-010 Transaxle Support Fixture

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Disconnect the negative battery cable.
2. Position the select lever park position.
3. Remove the battery.
4. Remove the air filter housing.
5. Install the engine support fixture DW110-060.
6. Disconnect the transaxle wiring harness from the transaxle.
7. Disconnect the Park/Neutral position switch electrical connector.
8. Remove the clip from the shift control cable and disconnect the shift control cable from the transaxle.
9. Remove the upper transaxle-to-engine mounting bolts.
10. Remove the left transaxle mounting bracket. Refer to «Left Transaxle Mounting Bracket Removal»(ref-257306-S15507504602007070900000) .
11. Raise and suitably support the vehicle.
12. Remove the centermember. Refer to «CENTERMEMBER ASSEMBLY REMOVAL»(ref-257288-S27524475642007070900000) .
13. Remove the impact bar. Refer to «IMPACT BEAM REMOVAL»(ref-257288-S41785055042007070900000) .
14. Drain the transaxle fluid.
15. Remove the oil cooler pipes from the transaxle. Refer to «Oil Cooler Pipes / Hoses Removal»(ref-257306-S30046725732007070900000) .
16. Remove the drive axle. Refer to «DRIVE AXLE ASSEMBLY REMOVAL»(ref-257299-S10203536352007070900000) .
17. Remove the starter motor. Refer to «STARTER REMOVAL»(ref-257293-S24857688332007070900000) .
18. Remove the flywheel to torque converter bolts.
19. Remove the rear transaxle mounting bracket bolts.
20. Support the transaxle assembly using the transaxle support fixture DW260-010.
21. Remove the oil pan flange-to-transaxle bolts.
22. Remove the left-lower engine-to-transaxle mounting bolts from the rear transaxle mounting bracket side.
23. Remove the right-lower engine-to-transaxle mounting bolts.
24. Remove the transaxle assembly.

Transaxle Assembly Installation

1. Install the transaxle into the vehicle.
2. Support the transaxle assembly using the transaxle support fixture DW260-010.
3. Install the right-lower engine-to-transaxle mounting bolts. Tighten: Tighten the right-lower engine-to-transaxle mounting bolts to 73 N.m (54 lb-ft).
4. Install the left-lower engine-to-transaxle mounting bolts. Tighten: Tighten the left-lower engine-to-transaxle mounting bolts to 73 N.m (54 lb-ft).
5. Install the oil pan flange-to-transaxle bolts. Tighten: Tighten the oil pan flange-to-transaxle bolts to 31 N.m (23 lb-ft).
6. Install the rear transaxle mounting bracket bolts. Tighten: Tighten the rear transaxle mounting bracket bolts to 65 N.m (48 lb-ft).
7. Install the flywheel to torque converter bolts. Tighten: Tighten the flywheel to torque converter bolts to 45 N.m (33 lb-ft).
8. Install the starter motor. Refer to «STARTER INSTALLATION»(ref-257293-S16114737922007070900000) .
9. Install the drive axle. Refer to «DRIVE AXLE ASSEMBLY INSTALLATION»(ref-257299-S20501949482007070900000) .
10. Install the oil cooler pipes from the transaxle. Refer to «Oil Cooler Pipes / Hoses Installation»(ref-257306-S06153017712007070900000) .
11. Install the impact bar. Refer to «IMPACT BEAM INSTALLATION»(ref-257288-S35833697012007070900000) .
12. Install the centermember. Refer to «CENTERMEMBER ASSEMBLY INSTALLATION»(ref-257288-S29733847042007070900000) .
13. Lower the vehicle.
14. Install the left transaxle mounting bracket. Refer to «Left Transaxle Mounting Bracket Installation»(ref-257306-S37890400632007070900000) .
15. Install the upper transaxle-to-engine mounting bolts. Tighten: Tighten the upper transaxle-to-engine mounting bolts to 73 N.m (54 lb-ft).
16. Install the clip to the shift control cable and connect the shift cable.
17. Install the Park/Neutral position switch electrical connector.
18. Connect the transaxle wiring harness to the transaxle.
19. Remove the engine support fixture DW110-060.
20. Install the air filter housing.
21. Install the battery.
22. Add the transaxle fluid. Refer to «Changing the Fluid»(ref-257306-S38151395012007070900000) .

Scheme 51

Scheme 52

Scheme 53

1. Remove the transaxle assembly. Refer to «Transaxle Assembly Removal»(ref-257306-S19054211392007070900000) .
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 DW230-130, snap ring and DW260-120.
3. Put the dial gauge sensor on Clutch B Adjusting Ring DW260-120.
4. Feed compressed air to Clutch E Adjust Ring DW260-130 via DW260-090 (C2 position).
5. Set dial gauge on DW260-120's upper surface to 0.
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 valve (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 (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 0.
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 = (2.6 + 2.35 + 2.34) / 3 = 2.36 mm After measuring the ring height of DW260-130, if the valve (RE) is 20.98 mm, EE = 20.98+2.36 = 23.34 mm

Measuring Installation Space F

Tools Required

DW260-110 Brake F Disc Clearance Measuring Bar

Scheme 54

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