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SUZUKI SQ416 SQ420 SQ625 JA627 JA420WD GRAND VITARA XL-7 UNIT REPAIR MANUAL – PDF DOWNLOAD
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The “Suzuki SQ416 SQ420 SQ625 JA627 JA420WD Grand Vitara XL-7 Unit Repair Manual” provides specific guidance for repairing individual components, ensuring meticulous unit repairs for optimal vehicle performance.
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Description
SUZUKI SQ416 SQ420 SQ625 JA627 JA420WD GRAND VITARA XL-7 UNIT REPAIR MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI SQ416 SQ420 SQ625 JA627 JA420WD GRAND VITARA XL-7 UNIT REPAIR MANUAL – PDF DOWNLOAD
Language : English
Pages : 393
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI SQ416 SQ420 SQ625 JA627 JA420WD GRAND VITARA XL-7 UNIT REPAIR MANUAL – PDF DOWNLOAD
Bookcover..................................................................................... 1 99501-65D50-01E............................................................................... 2 TOP....................................................................................... 0 Manual List............................................................................... 0 Important................................................................................. 2 WARNING/CAUTION/NOTE.................................................................. 2 Foreword.................................................................................. 3 Table of Contents......................................................................... 5 SECTION 7A................................................................................ 7 General Description................................................................... 8 Identification of Transmission Type............................................... 8 Transmission Case Components...................................................... 9 Gear Shifter Components........................................................... 10 Input and Counter Shaft Components................................................ 11 Unit Disassembly...................................................................... 12 Gear Shift Lever Case (4WD Model)................................................. 12 Gear Shift Lever Case (2WD Model)................................................. 13 Transmission Unit................................................................. 13 Sub-Assembly...................................................................... 17 Input shaft................................................................... 17 Main shaft.................................................................... 18 Upper case and shifter........................................................ 20 Component Inspection.................................................................. 20 Counter Shaft and Main Shaft Inner Parts.......................................... 20 Low and reverse scissors gear assemblies (if equipped)........................ 22 Upper Case and Shifter............................................................ 23 Rear Case......................................................................... 23 Unit Assembly......................................................................... 24 Gear Shift Lever Case (4WD Model)................................................. 24 Gear Shift Lever Case (2WD Model)................................................. 26 Sub Assembly...................................................................... 28 Main shaft.................................................................... 28 Counter shaft................................................................. 31 Upper case and shifter........................................................ 33 Transmission Unit................................................................. 36 Tightening Torque Specifications...................................................... 39 Required Service Material............................................................. 39 Special Tool.......................................................................... 40 SECTION 7A1............................................................................... 41 General Description................................................................... 42 Identification of Transmission Type............................................... 42 Components........................................................................ 42 Input and Counter Shaft Components................................................ 43 Transmission Case Components...................................................... 44 Gear Shifter Components........................................................... 45 Unit Disassembly...................................................................... 47 Gear Shift Lever Case............................................................. 47 Transmission Unit................................................................. 47 Sub-Assembly...................................................................... 56 Input shaft assembly.......................................................... 56 Main shaft assembly........................................................... 56 Counter shaft & reverse idle gear............................................. 57 Input shaft bearing retainer and oil seal..................................... 58 Transmission rear case........................................................ 58 Components Inspection................................................................. 59 Sub-Assembly...................................................................... 59 Input shaft assembly.......................................................... 59 Main shaft assembly........................................................... 60 Counter shaft and reverse idle gear........................................... 62 Unit Assembly......................................................................... 64 Gear Shift Lever Case............................................................. 64 Sub-Assembly...................................................................... 65 Input shaft assembly.......................................................... 65 Main shaft assembly........................................................... 66 Counter shaft and reverse idle gear........................................... 70 Input shaft bearing retainer and oil seal..................................... 71 Transmission rear case........................................................ 71 Transmission intermediate case and front case (location of knock and plug).... 73 Transmission Unit................................................................. 73 Tightening Torque Specification....................................................... 85 Required Service Material............................................................. 85 Special Tool.......................................................................... 86 SECTION 7A2............................................................................... 87 General Description................................................................... 88 Identification of Transmission Type............................................... 88 Transmission Components........................................................... 88 Transmission Case Components...................................................... 89 Input and Counter Shaft Components................................................ 90 Gear Shifter Components........................................................... 91 Unit Disassembly...................................................................... 92 Gear Shift Lever Case............................................................. 92 Transmission Unit................................................................. 93 Sub-Assembly......................................................................101 Input shaft assembly..........................................................101 Main shaft assembly...........................................................101 Counter shaft & Reverse idle gear.............................................103 Input shaft bearing retainer and oil seal.....................................103 Transmission rear case........................................................104 Components Inspection.................................................................105 Sub-Assembly......................................................................105 Input Shaft Assembly..........................................................105 Main shaft assembly...........................................................106 Counter shaft and reverse idle gear...........................................108 Unit Assembly.........................................................................110 Gear Shift Lever Case.............................................................110 Sub-Assembly......................................................................111 Input shaft assembly..........................................................111 Main shaft assembly...........................................................112 Counter shaft and reverse idle gear...........................................118 Input shaft bearing retainer and oil seal.....................................118 Transmission rear case........................................................119 Transmission intermediate case and front case (location of knock and plug)....120 Transmission Unit.................................................................121 Tightening Torque Specification.......................................................134 Required Service Material.............................................................134 Special Tool..........................................................................135 SECTION 7B1...............................................................................137 General Description...................................................................138 Torque Converter Diagnosis............................................................139 Stator Assembly Freewheels........................................................139 Stator Assembly Remains Locked Up.................................................139 Do Not Replace Converter for Following Conditions:................................139 Unit Repair...........................................................................140 Precautions.......................................................................140 Part Inspection and Correction Table..............................................140 Unit Disassembly..................................................................141 Sub-Assembly Repair...............................................................146 Oil pump......................................................................146 Overdrive (Planetary gear side)...............................................149 Overdrive (Case side).........................................................153 Forward clutch................................................................156 Direct clutch.................................................................160 Center support................................................................164 Planetary gears and output shaft..............................................170 Valve body assembly...........................................................174 Front upper valve body........................................................179 Rear upper valve body.........................................................181 Lower valve body..............................................................184 Unit Assembly.....................................................................188 Bearing and Race Installation Diagram.........................................201 Tightening Torque Specification.......................................................202 Required Service Material.............................................................202 Special Tool..........................................................................203 SECTION 7B2...............................................................................205 General Description...................................................................206 Torque Converter Diagnosis............................................................207 Stator Assembly Freewheels........................................................207 Stator Assembly Remains Locked Up.................................................207 Do Not Replace Converter for Following Conditions:................................207 Unit Repair...........................................................................208 Precautions.......................................................................208 Part Inspection and Correction Table..............................................208 Unit Disassembly..................................................................209 Components........................................................................210 Subassembly Oil Pump Assembly Components..........................................227 Clutch Drum & Input Shaft Assembly................................................232 Valve Body Assembly Components....................................................252 Unit Assembly.....................................................................253 Bearing and Race Installation Diagram.............................................278 Tightening Torque Specifications......................................................279 Required Service Material.............................................................280 Special Tool..........................................................................280 SECTION 7D................................................................................283 General Description...................................................................284 Identification of Transfer Type...................................................284 Components........................................................................285 Unit Repair...........................................................................287 Disassembly.......................................................................287 Component Inspection..............................................................293 Assembly..........................................................................294 Tightening Torque Specification.......................................................305 Required Service Material.............................................................306 Special Tool..........................................................................306 SECTION 7E................................................................................309 General Description...................................................................310 Component.........................................................................310 Unit Repair...........................................................................311 Disassembly Unit..................................................................311 Components Inspection.............................................................314 Differential left case........................................................314 Free axle hub.................................................................315 Actuator......................................................................315 Subassembly Adjustment and Reassembly.............................................316 Differential carrier..........................................................316 Differential case.............................................................316 Drive bevel pinion............................................................318 Assembly Unit.....................................................................321 Tightening Torque Specification.......................................................326 Required Service Material.............................................................327 Special Tool..........................................................................327 SECTION 7E1...............................................................................329 General Description...................................................................330 Component.........................................................................330 Unit Repair...........................................................................332 Disassembly Unit..................................................................332 Components Inspection.............................................................335 Differential left case........................................................335 Free axle hub.................................................................336 Actuator......................................................................336 Subassembly Adjustment and Reassembly.............................................337 Differential carrier..........................................................337 Differential case.............................................................337 Drive bevel pinion............................................................339 Assembly Unit.....................................................................343 Tightening Torque Specification.......................................................350 Required Service Material.............................................................350 Special Tool..........................................................................351 SECTION 7F................................................................................353 OTHER THAN H27 AND RHW ENGINE MODELS..................................................354 General Description...................................................................354 Unit Repair...........................................................................356 Disassembling Unit................................................................356 Component Inspection..............................................................359 Sub-Assembly Adjustment and Reassembly............................................359 Differential carrier..........................................................359 Differential case.............................................................359 Differential side bearing.....................................................362 Drive bevel pinion............................................................363 Assembling Unit...................................................................367 Tightening Torque Specification.......................................................371 Required Service Material.............................................................372 Special Tool..........................................................................372 H27 AND RHW ENGINE MODELS.............................................................374 General Description...................................................................374 Unit Repair...........................................................................375 Disassembling Unit................................................................375 Component Inspection..............................................................378 Sub-Assembly Adjustment and Reassembly............................................378 Differential carrier..........................................................378 Differential case.............................................................379 Differential side bearing.....................................................381 Drive bevel pinion............................................................382 Assembling Unit...................................................................386 Tightening Torque Specification.......................................................389 Required Service Material.............................................................389 Special Tool..........................................................................390 Copyright.................................................................................393 Bookcover................................................................................. 0
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