Transmission and Drivetrain: Service Precautions

Precautions in Diagnosing Trouble
^ Don't disconnect couplers from TCM, battery cable from battery, TCM ground wire harness from engine or main fuse before checking the diagnosis information (DTC, freeze frame data, etc.) stored in TCM memory. Such disconnection will clear memorized information in TCM memory.
^ Diagnostic information stored in TCM memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool. Before using scan tool, read its Operator's (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it. It is indistinguishable which module turns on MIL because not only ECM but also TCM turns on MIL. Therefore, check both ECM and TCM for DTC when MIL lights on. When checking TCM for DTC, keep in mind that DTC is displayed on the scan tool as follows depending on the scan tool used.
^ SUZUKI scan tool displays DTC detected by TCM.
^ Generic scan tool displays DTC detected by each of ECM and TCM simultaneously.
^ Be sure to read Precautions for Electrical Circuit Service before inspection and observe what is written there.
^ TCM replacement
^ When substituting a known-good TCM, check that all relays and actuators have resistance of specified value. Neglecting this check may result in damage to good TCM.
^ Communication of ECM, BCM, combination meter, keyless start control module (if equipped), ABS / ESP(R) control module, 4WD control module (if equipped), steering angle sensor ESP(R) model), Yaw rate G sensor ESP(R) model), TCM and DLC, is established by CAN (Controller Area Network). Therefore, handle CAN communication line with care.

General Service Procedure Information
When repairing automatic transaxle, it is necessary to conduct the on-vehicle test to investigate where the cause of the trouble lies first. Then whether overhaul should be done or not is determined. If the transaxle is disassembled without such preliminary procedure, not only the cause of the trouble would be unknown, but also a secondary trouble may occur and often time would be wasted.

Precautions for Disassembly and Reassembly
As the automatic transaxle consists of high precision component, the following cautions should be strictly observed when handling its parts in disassembly and reassembly.
^ Disassembling valve body assembly is prohibited essentially. However, a few parts can be disassembled. When disassembling valve body component parts, confirm whether their parts are allowed to disassemble or not referring to Valve Body Assembly Disassembly and Reassembly.
^ Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during dismounting and remounting.
^ Select a clean place free from dust and dirt for overhauling.
^ Place a rubber mat on the work bench to protect parts from damage.
^ Work gloves or shop cloth should not be used. (Use a nylon cloth or a paper towel.)
^ When separating the case joint, do not pry with a screwdriver or such but tap with a plastic hammer lightly.
^ Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during disassembly and reassembly.
^ Wash the disassembled parts in ATF (Automatic Transaxle Fluid) or kerosene (using care not to allow ATF or kerosene to get on your face, etc.) and confirm that each fluid passage is not clogged by blowing air into it. But use ATF to wash the friction plates resin washers and rubber parts.
^ Replace each gasket, oil seal and O-ring with a new one.
^ Apply ATF to sliding or rotating parts before reassembly.
^ A new friction plates should be soaked in ATF at least 2 hours before use.

Part Inspection and Correction Table