TRANSMISSION SUZUKI GRAND VITARA 2003 2.G Service Owner's Guide
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2003, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 2003 2.GPages: 801, PDF Size: 12.15 MB
Page 398 of 801
YH4
GRAND
VITARA
7A1
MANUAL TRANSMISSION (TYPE 2) 7A1-1
TYPE 2
GENERAL DESCRIPTION7A1-1 . . . . . . . . . . . . . .
DIAGNOSIS7A1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A1-3 . . . . . . . . . . . . . . . .
Gear Oil 7A1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A1-4. . . . . . . . . . . . . . . . . . .
Switches 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A1-4. . . . . . . . . . . . . . . . Dismounting / Remounting of
Trans. Unit 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A1-4 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A1-5 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A1-5 . . . . . .
The manual transmission consists of the input shaft,
main shaft, counter shaft and reverse gear which are
installed in the aluminum and castings cases. Its
gears are of forward five speeds in synchro mesh and
reverse one speed in sliding idler gear arrangement
system.
The main shaft gears are held by the needle bear-
ings and on them the synchronizer rings and syn-
chronizer sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.As the aluminum and castings cases are sealed with
liquid type gasket, it is necessary to use genuine seal-
ant or its equivalent on its mating surfaces when reas-
sembling them. Also, the case fastening bolts must be
tightened to specified torque by means of the torque
wrench and tightening over or below the specified
torque should be avoided.
The description under ON-VEHICLE SERVICE in this
section covers the transfer partially which is next to
the transmission as well, but their gear boxes are in-
dependent and each of them has its own drain and
level / filler plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A1
MANUAL TRANSMISSION
(TYPE 2)
CONTENTS
GENERAL DESCRIPTION
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7A1-2 MANUAL TRANSMISSION (TYPE 2)
DIAGNOSIS
ConditionPossible CauseCorrection
Gear slipping out of meshWorn shift fork shaft
Worn shift fork or synchronizer sleeve
Weak or damaged locating spring
Worn bearings on input shaft or main shaft
Worn chamfered tooth on sleeve or gear
Missing or disengagement of circlip(s)Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengageWeakened or broken synchronizer spring
Distorted shift shaft or shift forkReplace
Replace
Hard shiftingImproper clutch pedal free travel
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve or gear
Distorted shift shaftAdjust
Replace
Replace clutch cover
Replace
Replace sleeve and gear
Replace
NoiseInadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer ring
Damaged or worn chamfered tooth on
sleeve or gearReplenish
Replace
Replace
Replace
Replace
Page 400 of 801
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Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:
It is highly recommended to use SAE 75W-90 gear oil.
Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.
If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)
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7A1-4 MANUAL TRANSMISSION (TYPE 2)
SHIFT CONTROL LEVERS
Refer to SECTION 7A in this manual.
SWITCHES
Refer to SECTION 7A in this manual.
ENGINE REAR MOUNTING
Refer to SECTION 7A in this manual.
DISMOUNTING / REMOUNTING OF TRANS.
UNIT
Refer to the same item in SECTION 7A ªMANUAL TRANSMIS-
SIONº.
For tightening torque of filler and level / drain plug, refer to ªGear Oil
Inspection and Changeº of ªON-VEHICLE SERVICEº in this sec-
tion.
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
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MANUAL TRANSMISSION (TYPE 2) 7A1-5
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN´mkg-mlb-ft
Transfer oil filler / level and drain plugs232.317.0
Transmission oil filler / level and drain plugs383.827.5
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back-up light switch454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts505.036.5
Muffler to exhaust No. 2 pipe nuts505.036.5
Universal joint flange bolts505.036.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Shift control lever
Thread lock cement
THREAD LOCK CEMENT
SUPER 1333B
(99000-32020)
Shift control lever locating bolts
SealantSUZUKI BOND No. 1215
(99000-31110)Oil drain and filler / level plugs
Page 403 of 801
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7B1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-1
GENERAL DESCRIPTION7B1- 3 . . . . . . . . . . . . . .
CLUTCH / BRAKE FUNCTIONS 7B1- 5. . . . . . . . .
TABLE OF COMPONENT OPERATION 7B1- 6. . .
ELECTRONIC SHIFT CONTROL
SYSTEM 7B1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSIS7B1-17 . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION IN DIAGNOSING
TROUBLE 7B1-20. . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE 7B1-21. . . . . . . . . .
Customer Problem Inspection Form 7B1-23. . .
Malfunction Indicator lamp (MIL)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
ªO / D OFFº Lamp Check 7B1-24. . . . . . . . . . . . .
ªPOWERº Lamp Check 7B1-24. . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Clearance 7B1-24. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) Table7B1-24 . . .
Fail-Safe Table 7B1-25. . . . . . . . . . . . . . . . . . . . .
Visual Inspection 7B1-26. . . . . . . . . . . . . . . . . . .
A / T Basic Check 7B1-27. . . . . . . . . . . . . . . . . . .
Trouble Diagnosis Table 1 7B1-28. . . . . . . . . . .
Trouble Diagnosis Table 2 7B1-28. . . . . . . . . . . Trouble Diagnosis Table 3 7B1-29. . . . . . . . . . .
Scan Tool Data 7B1-30. . . . . . . . . . . . . . . . . . . . .
Inspection of PCM and Its Circuit 7B1-30. . . . .
Wire Harness and Connectors 7B1-30. . . . . . . .
Diagnostic Flow Table A-1 7B1-31. . . . . . . . . . .
Diagnostic Flow Table A-2 7B1-33. . . . . . . . . . .
Table B-1 ªO / D OFFº Light Circuit
Check 7B1-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-2 ªO / D OFFº Light Circuit
Check 7B1-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 ªPOWERº Light Circuit
Check 7B1-37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-4 ªPOWERº Light Circuit
Check 7B1-38. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0705 Transmission Range
Sensor (Switch) Circuit Malfunction 7B1-39. .
DTC P0715 Input / Turbine Speed
Sensor Circuit Malfunction 7B1-42. . . . . . . . . .
DTC P0720 Output Speed Sensor
Circuit Malfunction 7B1-44. . . . . . . . . . . . . . . . .
DTC P0741 TCC Solenoid Valve
Performance or Stuck Off 7B1-46. . . . . . . . . . .
DTC P0743 TCC Solenoid Electrical 7B1-47. .
DTC P0751 Shift Solenoid Valve-A (#1)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
DTC P0756 Shift Solenoid Valve-B (#2)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
SECTION 7B1
AUTOMATIC TRANSMISSION
(4 A/T)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
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7B1-2 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0753 Shift Solenoid-A (#1)
Electrical 7B1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0758 Shift Solenoid-B (#2)
Electrical 7B1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1875 4WD Low Switch Circuit
Malfunction 7B1-52. . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test 7B1-54. . . . . . . . . . . . . . . . . .
Stall Test 7B1-55. . . . . . . . . . . . . . . . . . . . . . . . . .
Road Test 7B1-56. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Road Test 7B1-57. . . . . . . . . . . . . . . . . .
Time Lag Test 7B1-57. . . . . . . . . . . . . . . . . . . . . .
Engine Brake Test 7B1-58. . . . . . . . . . . . . . . . . .
ªPº Range Test 7B1-58. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7B1-59 . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE 7B1-59. . . . . . . . . . . .
Fluid Level 7B1-59. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Change 7B1-60. . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Hoses 7B1-61. . . . . . . . . . . . . . . . . . .
A / T THROTTLE CABLE 7B1-61. . . . . . . . . . . . . . .
MANUAL SELECTOR ASSEMBLY 7B1-62. . . . .
SELECT CABLE 7B1-63. . . . . . . . . . . . . . . . . . . . . TRANSMISSION RANGE SWITCH 7B1-64. . . . .
A/T OUTPUT SPEED SENSOR 7B1-64. . . . . . . .
O / D CUT SWITCH 7B1-64. . . . . . . . . . . . . . . . . . .
SOLENOID VALVES 7B1-64. . . . . . . . . . . . . . . . . .
THROTTLE POSITION SENSOR 7B1-66. . . . . . .
POWER / NORMAL CHANGE SWITCH 7B1-66. .
OIL COOLER PIPES 7B1-67. . . . . . . . . . . . . . . . . .
BRAKE INTERLOCK SYSTEM 7B1-68. . . . . . . . .
Shift Lock Solenoid Control 7B1-68. . . . . . . . . .
Shift Lock Solenoid Control Operations 7B1-68
Shift Lock (Solenoid) Manual Release 7B1-69.
System Inspection 7B1-69. . . . . . . . . . . . . . . . . .
KEY INTERLOCK CABLE 7B1-71. . . . . . . . . . . . .
DISMOUNTING OF TRANSMISSION
(WITH TRANSFER IF EQUIPPED) 7B1-74. . . .
REMOUNTING 7B1-77. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7B1-78 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7B1-78 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7B1-79 . . . . . .
SPECIAL TOOLS7B1-79 . . . . . . . . . . . . . . . . . . . . . .
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AUTOMATIC TRANSMISSION (4 A / T) 7B1-3
1. Torque converter
2. Overdrive input shaft
3. Oil pump
4. Overdrive brake
5. Overdrive clutch
6. Forward clutch input shaft
7. Forward clutch
8. Direct clutch
9. One-way clutch
10. Second coast brake
11. Second brake
12. Reverse brake
13. Front planetary gear
14. Rear planetary gear
15. Overdrive planetary gear
GENERAL DESCRIPTION
This automatic transmission is a full automatic type with 3-speed plus overdrive (O / D).
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled
lock-up mechanism. The gear shift device consists of 3 sets of planetary gear units, 3 disc type clutches, 4 disc
type brakes and 3 one-way clutches. The gear shift is done by selecting one of 6 positions (ªPº, ªRº, ªNº, ªDº, ª2º
and ªLº) by means of the select lever installed on the floor. On the shift knob, there is an overdrive (O / D) cut switch
which allows shift-up to the overdrive mode (except at 4L) and shift-down from the overdrive mode. Also, by using
the P / N change switch located on the console box, it is possible to select the gear change timing of 2 modes, nor-
mal and power.
Page 406 of 801
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7B1-4 AUTOMATIC TRANSMISSION (4 A / T)
ItemSpecifications
Torque
conver-
terType
Stall torque ratio3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
2.4 (G16 engine) 2.0 (J20 engine) 1.9 (H25 engine)
Oil
pumpType
Drive systemTrochoid type oil pump
Engine driven
TypeForward 4-step, reverse 1-step planetary gear type
Shift position
ªPº range Gear in neutral, output shaft fixed,engine start
ªRº range Reverse
ªNº range Gear in neutral, engine start
ªDº range Forward 1st 2nd 3rd 4th (O / D)
(O / D ON) automatic gear change
ªDº range Forward 1st 2nd 3rd
(O / D OFF) automatic gear change
ª2º range (Normal mode) Forward 1st 2nd 3rd automatic gear
change
(Power mode) Forward 2nd 3rd automatic gear
change and fixed at 2nd gear
ªLº range Forward 1st 2nd 3rd reduction, and fixed at 1st gear
GearEngine typeG16 engineJ20 / H25 engines
change
device1st (low gear)2.8262.826device2nd (second gear)1.4931.493
Gear3rd (top gear)1.0001.000Gear
ratio4th (overdrive
4th gear)0.7300.689
Reverse (reverse
Reverse gear)2.7032.703
Control elements
Wet type multi-disc clutch 3 sets. . . . . . . . . .
Wet type multi-disc brake 4 sets. . . . . . . . . .
One-way clutch 3 sets. . . . . . . . . . . . . . . . . . .
TransferHi: 1.000 Lo: 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125 (G16 engine) 4.875 (J20 / H25 engines)
Lubrica-
tionLubrication systemForce feed system by oil pump
CoolingCooling systemRadiator assisted cooling (water-cooled)
Fluid usedAn equivalent of DEXRONIII
Page 407 of 801
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AUTOMATIC TRANSMISSION (4 A / T) 7B1-5
1. Overdrive clutch
2. Overdrive brake
3. Forward clutch
4. Direct clutch
5. Second coast brake
6. Second brake
7. Reverse brake
8. One-way clutch No.2
9. One-way clutch No.1
10. Overdrive one-way clutch
11. Overdrive input shaft
12. Forward clutch input shaft
13. Intermediate shaft
CLUTCH / BRAKE FUNCTIONS
Part NameFunction
Overdrive clutchMeshes overdrive carrier and overdrive sun gear.
Overdrive brakeFixes overdrive sun gear.
Overdrive one-way clutchMeshes overdrive carrier and overdrive sun gear only when driven
by engine.
Forward clutchMeshes input shaft and intermediate shaft.
Direct clutchMeshes input shaft with front sun gear and rear sun gear.
Second coast brakeFixes front sun gear and rear sun gear.
Second brakeFixes outer race of one-way clutch No.1, to prevent front sun gear
and rear sun gear from turning counterclockwise (reverse direction
of engine input rotation direction).
Reverse brakeFixes front planetary carrier.
One-way clutch No.1Prevents front sun gear and rear sun gear from turning counterclockwise
only when second brake is at work.
One-way clutch No.2Prevents front planetary carrier from turning counterclockwise.