Transmission Repair Procedure
Transmission repair procedure:1. Remove the transmission assembly according to the instructions in the Forenza service manual (Transaxle Assembly Removal and Installation).
2. Place transmission on a clean work bench.
3. Remove the oil pan from the transmission.
4. Use a T27 torx bit tool to remove the speed sensor (a).
5. Remove the valve body from the transmission by removing the 7 indicated bolts that attach the valve body to the transmission. Do not loosen or remove the other bolts.
6. Carefully remove the valve body from the transmission taking care not to damage the rubber seal indicated. This seal allows fluid to actuate the C Piston.
NOTICE
If you damage the seal the transmission may exhibit the same symptoms when it is reassembled!
Be careful not to damage the seal.
7. This picture shows the rubber seal in the pressure line to the C Piston as indicated in step 6. With your fingertips or a small blunt tool gently pull the seal out about 5 mm above the surface of the case. Failure to do so will obstruct removal of the C Piston and will cause damage to the seal inside the transmission.
8. Using a 13 mm socket, remove the rear cover assembly. During removal, a thrust bearing and washer may fall out. Locate these two parts and set them aside.
9. Carefully remove the input shaft assembly using two hands to pull it straight out.
10. Remove the C-clip securing C Piston.
NOTE:
This large clip is under tension inside the case.
11. Remove the C Piston by placing your fingers around the inner edge of the piston and pulling it straight out.
12. Remove the disk set C & D using your fingers and pulling the disk set straight out.
13. Remove wave washer from the back side of the disk set C & D assembly, apply assembly lubricant (Assemblee Goo(TM)) as shown and set aside for reassembly.
14. Discard the old disk set C & D.
15. Submerge the new disk set C & D assembly in a pan with clean transmission fluid coating all of the plates with transmission fluid.
16. Note the location of the alignment slots on both sides of the inner transmission housing.
17. Make sure the oil seal is not damaged and confirm that the seal is positioned slightly lower than flush with the surface of the housing.
18. Note the locations of the alignment keys on the new disk set C & D assembly.
19. Locate the wave washer removed from the old disk set C & D assembly and attach it to the back of the new disk set C & D assembly using assembly lubricant to hold it in place (Refer to step 13 for location of assembly lubricant).
20. Install the disk set C & D assembly (with the wave washer) into the transmission case aligning the keys with the slots in the case.
21. Submerge the new C Piston into clean transmission fluid turn it upside down (black seal side down) and carefully insert it into the cylinder.
22. Locate the alignment key on the C Piston cylinder and the associated alignment slot on the inside of the case.
23.With the seal side of the cylinder away from you align the key with the slot and install the cylinder (with the C Piston inside) into the transmission.
24. Install the snap ring into the groove by hand. The ring should easily snap into the groove.
25. Install the planetary gear assembly into the transmission case by gently rocking and rotating it back and forth to align the teeth of the clutch plates. You should hear a clunk sound when it finally seats itself.
26.Apply assembly lubricant to the input shaft bearing surface and bearing. Then place the bearing onto the input shaft for assembly.
27. Make sure that the bearing is seated and positioned as shown. Refer to the service manual to confirm the correct orientation of both bearings.
28. Insert the sun gear onto the input shaft.
29. Check the input shaft and make sure that the metal piston ring is connected and apply assembly lubricant making sure to liberally coat the piston ring.
30. Install the input shaft assembly into the transmission case by gently rotating the input shaft back and forth to make sure that it seats. You will hear a clunk sound when it is seated properly.
31. When seated correctly the edge of the cylinder will be 8 mm (0.315") below flush with the edge of the transmission case.
NOTE:
If the cylinder is not fully seated and below the level of the transmission housing do not attempt to install the cover.
Continue to rotate the input shaft back and fourth allowing it to drop all the way in, making it 8 mm (0.315 in.) minimum below the level of flush with the machined surface of the case.
32. Lubricate the case cover 0-ring with assembly lubricant or clean transmission fluid then attach the mainshaft bearing and washer to the cover using assembly lubricant as illustrated above.
33. Install the case cover on the transmission case using the five 13 mm bolts removed in step 8 and tighten to 17 lbf-ft (23 Nm).
34. Prepare to reinstall the valve body by checking the piston seal. Confirm the seal is not damaged. With your hands gently press the piston seal back into the housing.
35. Loosely install the valve body to the transmission case using the 7 bolts.
NOTE:
Make sure that the solenoid wire harness is not pinched between the transmission case and the top or bottom of the valve body.
36. Connect the manual shift shaft, located on the valve body to the range selector lever.
37. Tighten the valve body mounting bolts, working from the center outward and tighten to 71 lbf-in (8 Nm).
NOTICE
Over-tightening the valve body fasteners can cause the valve body to malfunction.
Do not exceed the 71 lbf-in. (8 Nm) tightening torque for the valve body mounting bolts.
If you mistakenly loosened/removed any of the other valve body fasteners, torque them to 53 lbf-in. (6 Nm).
38. Install the input speed sensor and tighten to 71 lbf-in (8 Nm).
39. Install the oil pan and tighten pan bolts to 53 lb-in (6 Nm)
40. Reinstall the transmission assembly according to the instructions in the Forenza service manual (Transaxle Assembly Removal and Installation).
41. After the transmission is installed, use the special tool DW260-070 (available on SuzukiPitstopPlus.com) AUTO/TRANSAXLE OIL PLUG & 8MM SQUARE DRIVE SOCKET REMV/INST, to remove the oil tiller plug.
42. With the engine off and cold, add approximately 5 liters of Suzuki recommended transmission fluid into the transmission until the fluid starts to spill out of the filler hole.
43. Leaving the filler hole open, start the engine and shift the transmission through all the gears.
44. While the engine is running, add more transmission fluid until it starts to spill out the filler hole.
45. Reinstall the filler plug.
46. Perform transmission "TCM Learned Initialize" (refer to Technical Service Bulletin Forenza Transmission TS 06 Required Automatic Transmission Control Module Initialization Procedure) and "Tooth Error Correction" procedure (refer to Technical Service Bulletin Forenza Engine TS 02 Crankshaft Position Variation Learn).
47. Test drive the vehicle for about 2 miles varying the speed between 20 mph and 45 mph to confirm the transmission shifts properly through all the gears ranges.