AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30 Article Text

1995 Suzuki Sidekick For saer Nira Sakhalin Russia 693013
Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, January 13, 2002 07:54PM

ARTICLE BEGINNING

AUTOMATIC TRANSMISSIONS Hydra-Matic 3L30 Geo; Tracker Suzuki; Sidekick
APPLICATION & LABOR TIMES

APPLICATION & LABOR TIMES
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Vehicle Application Geo 1995-96 Tracker 2WD .................. 4WD .................. Suzuki 1995-96 Sidekick 2WD .................. 4WD ..................

Labor Times (1) R & I (2) Overhaul

Trans. Model

4.8 ......... 7.1 5.8 ......... 7.1

......... .........

3L30 3L30

4.8 ......... 7.1 5.8 ......... 7.1

......... .........

3L30 3L30

(1) - Removal and installation of transmission from vehicle chassis. (2) - Bench overhaul time for transmission. DOES NOT include removal and installation.
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IDENTIFICATION

Transmission is identified by identification plate attached to transmission case, located on left side, above oil pan. Vehicle Identification Number (VIN) may also be used in identifying transmission. VIN locations are at top left of instrument panel and driver's-side door post. VIN is used to ensure correct application of component parts and assemblies.
DESCRIPTION & OPERATION

Automatic transmission provides 3 forward speeds and reverse. Main internal components are; oil pump, Torque Converter w/Clutch (TCC), reverse clutch, 2nd clutch, 3rd clutch, one-way clutch (sprag type), compound planetary gear set, low brake, governor and valve body. See Fig. 1.

Gear shifting is controlled by valve body. Components that regulate shifting schedules are; governor, modulator and kick-down valve. TCC is operated by an electric solenoid. TCC solenoid operation depends on signals provided by the Engine Coolant Temperature (ECT) sensor, brake switch, Throttle Position (TP) sensor, Vehicle Speed Sensor (VSS) and gear position.

Fig. 1: Cross-Sectional View Of 3L30 Transmission Courtesy of Suzuki of America Corp.
LUBRICATION & ADJUSTMENTS

See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 2)1995 Suzuki Sidekick AUTO section.

TROUBLE SHOOTING

NOTE:

Poor engine performance can have a negative effect on transmission performance.

Preliminary Checks Ensure fluid level is correct. Inspect and adjust shift linkage and park/neutral position switch (if necessary). Check idle speed RPM and adjust as necessary. Road test vehicle to ensure proper engine performance.
SYMPTOM DIAGNOSIS

Low Fluid Level Check for fluid leak out of filler tube, external fluid leak(s) and faulty vacuum modulator. Fluid Leak From Filler Tube Check for high fluid level, engine coolant in transmission fluid, pinched breather hose and leak in oil pump suction circuit. Low Fluid Pressure Check for low fluid level, clogged oil pump screen, leak in oil pump suction circuit, leak in oil pressure circuit, pressure regulator valve malfunction and/or missing valve body sealing ball (plug). High Fluid Pressure Check for leaking modulator vacuum line, malfunctioning modulator, leaking engine vacuum system or faulty pressure regulator valve. Excessive Smoke From Exhaust Inspect vacuum modulator. No Torque Converter Clutch Application Check for 12-volt power supply to transmission, good ground in transmission, faulty harness connections, defective pressure switch, sticking converter clutch control valve, cut or leaking TCC solenoid valve "O" ring, damaged or mispositioned oil pump wear plate, incorrectly tightened converter housing-to-oil pump bolts and/or cut turbine shaft "O" ring.

No Torque Converter Clutch Release Or Shudder Check for sticking TCC control valve, restricted TCC apply passage, low fluid level, low fluid pressure, poor engine performance AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 3

low fluid level. Upshifting Under Full Throttle Only Check for faulty modulator. AUTO TRANS D . No Vehicle Movement In Any Gear Position Check for parking pawl disengagement. Vehicle Movement In Neutral Position Check for improperly adjusted shift selector cable. engine vacuum leak and/or stuck kick-down valve or cable. No Vehicle Movement In Any Range Check fluid level. broken planetary gear carrier and/or low band adjustment. disconnected manual valve link or manual select shaft inner lever. No 1-2 Upshift Check for stuck governor valves. Vehicle Movement Under RPM Increase Only Check for stuck servo piston. No 2-3 Upshift Check for stuck 2-3 shift valve and/or leak in governor pressure circuit. Upshifting Under Part Throttle Only Check for stuck kick-down pressure regulator valve and/or misadjusted kick-down cable. leak in governor pressure circuit and/or clogged governor oil screen. No Vehicle Movement In "D" Or "2". stuck pressure regulator valve or missing valve body sealing ball (plug). pressure regulator valve stuck in open position or faulty oil pump. missing oil pump screen or missing valve body sealing ball (plug). Vehicle Moves In "L" Or "R" Input sprag installed backwards or sprag failure. 1-2 shift valve stuck in 1st position. faulty oil pump. No Movement In "R" Only Check for reverse clutch failure.and/or cut turbine shaft "O" ring. leaking modulator vacuum line. broken input shaft. incorrect modulator valve. clogged oil pump screen. leaking oil pump seal rings. Heavy Jerking During Initial Vehicle Movement Check for low fluid pressure.

stuck 1-2 accumulator valve and/or broken 2nd clutch spring cushion. leaking 3rd clutch piston seals. Hard Disengagement Of Select Lever From "P" Position Missing parking lock actuator guide bushing or stuck manual select shaft. 1-2 Shift Check for low fluid pressure. Transmission Immediately Shifts Into Lower Gear Once Throttle Is Eased After Full Throttle Upshifting Check for kick-down valve stuck in open position. Engine Flare. 5) . 2-3 Shift Check for low fluid pressure.HYDRA-MATIC 3L30Article Text (p. broken or cracked 2nd clutch piston. loose connection at manual valve or pressure loss at governor.Vehicle Movement In "1". missing valve body sealing ball (plug). Transmission Shifts Into Lower Gear At Higher Speeds Manual select shaft spring pin dropped out. No Part Throttle 3-2 Downshift At Low Vehicle Speeds Check 3-2 downshift control valve. Engine Flare. 2nd clutch piston plates worn or leaking oil pump hub sealing rings. low band adjustment. 3rd clutch piston check ball stuck open. AUTO TRANS DIAGNOSIS . Harsh 3-2 Manual Downshift Check for stuck open high speed downshift valve and low band adjustment. No Vehicle Movement In "2" Or "R" 1st and reverse control valve stuck in 1st or "R" position. No Forced Downshift Check kick-down cable adjustment and kick-down pressure regulator valve. Harsh 2-3 Shift Check for high fluid pressure or incorrect low band adjustment. 2nd clutch piston check ball stuck open. stuck kickdown cable and/or spliced modulator vacuum line. Harsh 1-2 Shift Check for high fluid pressure. leaking 2nd clutch piston seals. broken or cracked 3rd clutch piston and/or worn input shaft bushing. missing valve body sealing ball (plug).

... One-Way Clutch & Low Band 2nd Gear ... Buzzing Noise Clogged oil pump screen................ 6)1995 Suzuki SidekickFor saer Nira Sakhalin Ru ........ No Engine Braking In "2" Range Check select cable adjustment. Screeching Noise When Starting Torque converter failure.......Harsh 3-2 Coasting Downshift Check for stuck open low speed downshift timing valve..................... loose planetary carrier lock plate.. defective thrust bearing... Transmission Does Not Hold In Park Improperly adjusted select cable.... High Speed Downshift Flare Check for low fluid pressure or low band adjustment Low Speed Forced Downshift Flare Check for low fluid pressure..... closed high speed downshift timing valve and/or one-way clutch does not lock on 3-1 downshifting.... low band adjustment......... TRANSMISSION COMPONENT APPLICATION CHART ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Selector Lever Position Elements In Use "D" (Drive) 1st Gear .... No Engine Braking In Low Check select cable adjustment and/or stuck manual low control valve.... 3rd Clutch & One-Way Clutch "2" (Intermediate) 1st Gear ..HYDRA-MATIC 3L30Article Text (p.... broken parking lock actuator spring or damaged parking pawl and governor hub. Excessive Noise In All Ranges Check backlash between sun gear and planetary gears... 2nd Clutch & Low Band 3rd Gear ..... 2nd Clutch....... Hissing Noise Shortly Before 1-2 Upshift Reverse clutch spring cushion wearing into transmission case. Short Vibrating.. worn bushings or loose converter housing bolt contacting torque converter. One-Way Clutch & Low Band 2nd Gear ........ 2nd Clutch & Low Band AUTO TRANS DIAGNOSIS ........

.... If no problems are found.. near kick panel. 1) Ensure ignition is off... One-Way Clutch "P" (Park) ....... Check Blue/Black wire between TCC relay and main relay for an open or short to ground... go to next step... Access Powertrain Control Module (PCM).. Repair as necessary. Repair as necessary... check TCC relay.. 3rd Clutch & One-Way Clutch "N" (Neutral) . go to step 4). Reverse Clutch.... AUTO TRANS DIAGNOSIS - . Disconnect PCM 22-pin harness connector (C2 on Geo or E34 on Suzuki). 3) Start engine and allow it to reach normal operating temperature.. If no problems are found..... 2) Turn ignition on..... Using a voltmeter.. One-Way Clutch ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ELECTRONIC TESTING TORQUE CONVERTER CLUTCH (TCC) .."L" (1st Gear) 3rd Clutch.... Repair any engine performance-related DTCs first.. See TORQUE CONVERTER CLUTCH (TCC) RELAY. Shift selector lever to "D" position and accelerate. NOTE: Before performing the following procedures........ substitute a known-good PCM and retest system. connect a scan tool to Data Link Connector (DLC) and retrieve any stored Diagnostic Trouble Codes (DTCs). Disconnect TCC relay. 16 (White/Yellow wire).. On Suzuki. One-Way Clutch & Low Band "R" (Reverse) ....... Replace if necessary.... If relay is okay.. See appropriate wiring diagram in WIRING DIAGRAMS to aid in component... located under left side of instrument panel.. If relay is okay.. See TORQUE CONVERTER CLUTCH (TCC) RELAY.... Check for blown fuses and repair short(s) to ground if necessary. If battery voltage is not present.. 6) Turn ignition off. check TCC relay...... substitute a known-good PCM and retest system. Check White/Yellow wire between TCC relay and PCM for an open or short to ground.. go to step 5). 4) Check for poor TCC relay harness connection..... If voltage reading decreases to 0-1 volt at about 47 MPH.. If voltage reading is not as specified. On Geo. Turn ignition on... measure voltage between ground and PCM harness connector C2 or E34. a DTC P0740 or P0770 identifies a TCC solenoid malfunction. Raise and support vehicle to allow rear wheels to spin freely...... wire color and terminal identification.... 5) Check for poor harness connections at PCM.. If battery voltage is present... a DTC P0740 identifies a TCC electrical circuit malfunction.. Replace if necessary. terminal No. go to step 6).

3. Replace relay if it does not test as specified. Replace if necessary. Oil should exhaust from solenoid. 2) Apply battery voltage to terminal No. If reading is not as specified. Fig. go to next step. 2 (Black/White wire). 2 and 4. 2) Using fused jumper wires. 2. Remove TCC relay. repair open in Black/White wire. TORQUE CONVERTER CLUTCH (TCC) SOLENOID 1) Remove TCC solenoid from transmission. check for low fluid pressure. 8) Check White wire between TCC relay and TCC solenoid for an open or poor connection. TORQUE CONVERTER CLUTCH (TCC) RELAY 1) Turn ignition off. Continuity should not be present between terminals No. Solenoid should click and not allow any oil to exhaust. add ATF to remaining oil passage. Repair as necessary. 2: Identifying TCC Relay Terminals Courtesy of Suzuki of America Corp. Using an oiler. Using Orifice Plug (09922-85811). See Fig. 7) Check TCC solenoid. misadjusted kick-down cable or other internal transmission problems. Continuity should now be present between terminals No. See Fig. Replace TCC solenoid if it does not test as specified. measure voltage between ground and TCC relay harness connector terminal No. If solenoid is okay. AUTO TRANS . If reading is battery voltage. apply battery voltage and ground to TCC solenoid terminals. 1. 3. 1 and 3.Using a voltmeter. 2 and 4. If no problem is found. Resistance should be 90-110 ohms. go to next step. See TORQUE CONVERTER CLUTCH (TCC) SOLENOID. Using an ohmmeter. and ground terminal No. plug one oil passage on TCC solenoid. measure resistance between relay terminals No.

Fig. 1) Engine and transmission must be at normal operating .HYDRA-MATIC 3L30Article Textis within specification Nira Sakhalin Ru temperature. Start engine and ensure idle RPM (p. Using stop watch. measure time until engagement shock is felt when selector lever is shifted from "N" to "D" position. Apply service and parking brakes. 9)1995 Suzuki SidekickFor saer with A/C off. TESTING TIME LAG TEST AUTO TRANS DIAGNOSIS . 3: Testing TCC Solenoid Courtesy of Suzuki of America Corp.

Shift vehicle into park. Accelerate vehicle and ensure vehicle upshifts from 1st to 2nd. very lightly apply brake pedal.2) Allow one minute intervals between tests. See LINE PRESSURE SPECIFICATIONS table. HYDRAULIC PRESSURE TESTS Line Pressure Test 1) Ensure transmission fluid is at normal operating temperature. TCC should disengage. Connect appropriate pressure gauge to line pressure test port on transmission. Depress accelerator pedal to Wide Open Throttle (WOT). Lightly accelerate vehicle to confirm reverse operation. Unbolt cross member and lower transmission to gain access to pressure port. 2) Depress accelerator pedal to 1/2 position. Disconnect modulator vacuum line. Perform time measurements 2 more times and calculate average value.5 seconds. Shift transmission into drive. Allow engine to idle (approximately 1500 RPM). Accelerate to cruising speed until TCC is applied. Check line pressure and record pressure reading. Place a wood block between distributor housing and firewall to prevent damage to distributor cap when lowering transmission. 3) Release accelerator pedal. Raise and support vehicle. Time lag should be less than 1. Shift transmission to "D" position. Ensure transmission shifts into lower gears and engine braking occurs. then into low position.2 seconds. Repeat test procedure to test time lag when selector lever is shifted from "N" to "R" position. inspect internal components. Repeat test in "2" and "L" position. Repeat test in "2" and "L" position. Check line pressure and record pressure reading. Using left foot. Stop vehicle on slight incline.HYDRA-MATIC 3L30Article Text (p . Release brake and allow wheels to accelerate to approximately 28 MPH. manually shift into 2nd gear. If results are not within specification. As vehicle is slowing down. TCC should apply while in 3rd gear. 2) Support transmission with jack. then transmission should downshift to 2nd gear. Stop vehicle and shift into reverse. See Fig. Do not hold engine at WOT for more than 5 seconds. LINE PRESSURE SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ AUTO TRANS DIAGNOSIS . 4. Ensure vehicle does not move. 4) Apply brakes. ROAD TEST 1) Ensure vehicle is at operating temperature. TCC should release. Time should be less than 1. 3) Apply service brake and shift transmission to "D" position. then to 3rd gear.

.. Slips in "L"......5) "L" ........... 87-102 (6.. 95 (6........................9) "L" ..4) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Fig............ Hold modulator so vacuum fitting points downward.....0-7...... 161-177 (11... 118 (8...... 54-63 (3.... Replace modulator if full of transmission fluid...................................Shifter Position psi (kg/cmý) Idle Speed Geo "D" & "2" .............7) Suzuki "D" & "2" .............3-12........................ 100-112 (7..................3) "L" ...8-4........2) Suzuki "D" & "2" ... Burnt transmission fluid..... "D" and "R".. 1) Remove modulator............1-7.......... Soft upshifts and downshifts................ 65 (4.............. 4: Identifying Pressure Test Port Courtesy of Suzuki of America Corp...... Transmission overheating. 160 (11.6) "L" ........... Delayed upshifts...... AUTO TRANS DIAGNOSIS - . VACUUM MODULATOR NOTE: * * * * * * A faulty vacuum modulator can cause: Harsh upshift and downshifts...........1) WOT Geo "D" & "2" ...

KICKDOWN CABLE/THROTTLE CABLE For kickdown or throttle cable adjustment. see REMOVAL & INSTALLATION in appropriate AUTOMATIC TRANSMISSION REMOVAL article. Install extension housing and new gasket. Replace if necessary. Perform the following tests to check torque converter condition. 3) Remove snap ring. see ADJUSTMENTS in appropriate AUTOMATIC TRANSMISSION SERVICING article. Remove drive shaft. Apply 20 In. Installation To install. speedometer cable and speedometer driven gear. Hg of vacuum.HY . AUTO TRANS DIAGNOSIS . Remove transmission-to-cross-member bolts and rear mount from extension housing. REMOVAL & INSTALLATION For transmission removal and installation procedure. Ensure modulator operates and holds vacuum. Ensure output shaft bolt hole is aligned with governor assembly.2) Connect vacuum pump. ON-VEHICLE SERVICE EXTENSION HOUSING & GOVERNOR ASSEMBLY Removal 1) Raise and support vehicle. TORQUE CONVERTER NOTE: Torque converter is a sealed unit and must be serviced as a complete assembly. Place reference marks on drive shaft and companion flange. Remove governor assembly (if applicable). On 4WD vehicles. see ADJUSTMENTS in appropriate AUTOMATIC TRANSMISSION SERVICING article. remove transfer case and adaptor. Torque converter and transmission cooler must be thoroughly cleaned and flushed if transmission fluid is contaminated. speedometer drive gear and remaining snap ring from output shaft. 2) Remove extension housing bolts and remove extension housing. Support transmission with jack. SHIFT LINKAGE For shift linkage adjustment. Clean all bolt threads. Note bolt length and location. See appropriate article in AXLE SHAFTS & TRANSFER CASES section. reverse removal procedure.

Separate 2nd clutch from 3rd clutch. Remove servo assembly with spring and rod. Remove 2nd and 3rd clutch assemblies. Remove manual detent roller assembly. 3) Remove compressor. Remove TCC solenoid and harness assembly. See Fig. Remove speedometer gear retaining snap ring. See Fig. link. TRANSMISSION DISASSEMBLY 1) Remove oil pan and filter. Remove "O" ring from input shaft. Remove low brake band and any remaining thrust bearing and washer.HYDRA-MATIC 3L30Article Text (p. Remove Park/Neutral Position (PNP) switch.STATOR (ONE-WAY CLUTCH) TEST Insert finger into splined inner race of roller clutch and try to turn race in both directions. 13)1995 Suzuki SidekickFor saer Nira Sakhalin R . Remove thrust bearing from top of sun gear if bearing did not stay with planetary gear. 6. Using Servo Compressor (09927-66020 or J-23075). Remove reinforcement plate under TCC solenoid. Replace torque converter if clutch fails test. AUTO TRANS DIAGNOSIS . Remove lever and select shaft. 8. 2) Unbolt and remove valve body with manual valve. 8. Remove modulator and modulator plunger. 6) Remove housing. Remove servo cover. Remove electrical harness connector. separator plate and gaskets. Clutch should lock when rotated counterclockwise. Pull roll pin from manual select shaft. 7) Remove planetary gear. 7. Remove rear sun gear assembly. See Fig. and turn freely when rotated clockwise. See Fig. Remove bolts securing converter housing to transmission case. Remove governor from hub. See Fig. Remove check ball in transmission case. Remove roll pin from kickdown valve sleeve. 5. oil pump and reverse clutch piston as complete assembly. 5) Remove governor hub. Place a metal plate between manual select shaft inner lever and case. 8) Remove manual select shaft inner lever and parking lock actuator assembly. Remove remaining reverse clutch plate and pressure plate. Loosen nut on end of shaft and remove. Remove remaining kickdown valve components. Remove small filter screen from hub. gear and snap ring. compress servo piston assembly and remove snap ring. 4) Remove extension housing or transfer case. Remove governor pressure switch from valve body.

6: Compressing Servo Piston Assembly Courtesy of Suzuki of America Corp. 5: Locating Transmission Case Check Ball Courtesy of Suzuki of America Corp. 14)1995 Suzuki SidekickFor saer Nira Sakhalin R . Fig.HYDRA-MATIC 3L30Article Text (p. AUTO TRANS DIAGNOSIS .Fig.

15)1995 Suzuki SidekickFor saer Nira Sakhalin R . AUTO TRANS DIAGNOSIS .Fig.HYDRA-MATIC 3L30Article Text (p. 7: Exploded View Of Modulator & Kick-Down Assemblies Courtesy of Suzuki of America Corp.

HYDRA-MATIC 3L30Article Text (p. 16)1995 Suzuki SidekickFor saer Nira Sakhalin R Fig.AUTO TRANS DIAGNOSIS . . 8: Exploded View Of Transmission Assembly Courtesy of Suzuki of America Corp.

(mm) Color AUTO TRANS DIAGNOSIS . VALVE BODY SPRING SPECIFICATIONS (GEO) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Description Diameter In. Inspect valve springs for damage. reverse disassembly procedures. Ensure valves move freely. Ensure all valve body passages are clear.HYDRA-MATIC 3L30Article Text (p. See appropriate VALVE BODY SPRING SPECIFICATIONS table. Lay all components in sequence during removal for reassembly reference. Polish with crocus cloth. Inspect valves for scoring or roughness. Measure spring free length and outer diameter. Disassembly Remove manual valve. Ensure valves slide freely in bores. Fig. nicks or burrs. Individually remove each valve retaining pins. (mm) Free Length In. 10. See Fig. Inspect valves for scoring. Remove components from governor body. squareness and collapsed coils. 17)1995 Suzuki SidekickFor saer Nira Sakhalin R . To assemble. VALVE BODY ASSEMBLY NOTE: All valve body components must be installed in original location. 9: Exploded View Of Governor Assembly Courtesy of Suzuki of America Corp. See Fig. Remove all components.COMPONENT DISASSEMBLY & REASSEMBLY GOVERNOR BODY Disassembly & Reassembly Depress secondary valve spring and remove secondary valve spring retainer. Dry with compressed air. Replace spring if not within specification. Inspection Clean all parts in solvent. 9.

438 (11.1) .1) ... ......5) ... 3-2 Control Valve .. ..48 (12.....313 (33.4) .. 1....1) .750 (19.5) ....0) ......... (mm) Color 1-2 Shift Control Valve ....438 (11. 2-3 Shift Control Valve ... . ..... 1...1-2 Shift Control Valve ...3) ............ Ensure valves move freely and snap back when moved...30 (33) ..52 (13.1) ...7) ....... Detent Pressure Regulator .... 2........... (1) ....5) . Black 1-2 Shift Valve .........31 (8) ......500 (12.Information not available from manufacturer........47 (12) .... .500 (12....625 (41......7) ....... Lt. 1. 18)1995 Suzuki SidekickFor saer Nira Sakhalin R .5) ....34 (34) .... 1...3) .61 (41) .....4) .. ...... Use a liberal amount of transmission fluid...2) ....HYDRA-MATIC 3L30Article Text (p.2) .9) .... 1-2 Accumulator Valve ......3) .... AUTO TRANS DIAGNOSIS .... 1...3) .67 (17) . ...375 (34. (1) (1) (1) (1) (1) (1) (1) (1) (1) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ VALVE BODY SPRING SPECIFICATIONS (SUZUKI) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Description Diameter In.....4 (10........ (mm) Free Length In......3) .. .... Blue/Pink Low Speed Downshift Valve . .. ...53 (13... 1........ ... 1..4 (10...4) .. Green/Yellow ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Reassembly Install valves..438 (11.......... 2..72 (18. 1.. Low Reverse Control Valve ..9) .. (1) ... High Speed Downshift Valve ........ 1.. Low Speed Downshift Valve .. 2..... springs..1) ...... ... Brown/Yellow 3-2 Control Valve ....... .......31 (33. ......687 (17....13 (54) ....750 (44.. 1..............063 (27. Blue/Green Low Reverse Control Valve ...... Light Green 1-2 Accumulator Valve ..............41 (10....750 (44.....438 (11........ ... ........ plugs and retaining pins in proper order and location. .. .46 (62.. .....313 (33. Silver Detent Pressure Regulator .72 (18.....3) .... 1-2 Shift Valve . (1) ......438 (61.... 1..3) ......... Blue 2-3 Shift Control Valve . Yellow/Green High Speed Downshift Valve ..57 (40) ... 1......

reverse disassembly procedure.HYDRA-MATIC 3L30Article Text (p. 11. Clean all parts and inspect for wear or damage. Compress piston and remove clip. To reassemble. 10: Exploded View Of Valve Body Assembly Courtesy Of Suzuki of America Corp. AUTO TRANS DIAGNOSIS . 19)1995 Suzuki SidekickFor saer Nira Sakhalin R . Fig. 11: Exploded View Of Servo Piston Assembly Courtesy of Suzuki of America Corp. See Fig.Fig. SERVO PISTON ASSEMBLY Disassembly & Reassembly Loosen adjusting stud nut and remove.

Install NEW oil seal in converter housing. See TORQUE SPECIFICATIONS. See Fig. Tighten bolts to specification. Inspection Clean all components in solvent. Place converter housing on oil pump. Inspect valves and valve bores for scoring. Loosely install bolts. 2) Using appropriate compressor.08 mm). Clearance should be . 20)1995 Suzuki SidekickFor saer Nira Sakhalin R Disassembly . Remove bolts and separate converter housing from oil pump. Polish valves with crocus cloth (as needed). Place springs onto piston. OIL PUMP & REVERSE CLUTCH ASSEMBLY Disassembly 1) Remove selective thrust washer from oil pump shaft (if necessary). remove valve assemblies from oil pump by removing retaining pins. 2ND CLUTCH ASSEMBLY AUTO TRANS DIAGNOSIS . Mark pump gears with reference marks and remove gears. 12. Remove snap ring.CONVERTER HOUSING.HYDRA-MATIC 3L30Article Text (p. Install oil pump Aligning Sleeve (09927-66010 or J-23082-01) through converter housing into pump. Remove pump wear plate. burrs and nicks.0005-. Remove reverse clutch piston.02-.0032" (. 8. Fig. inspect pump to gear clearance. If necessary. Install spring seat. Reassembly 1) Place wear plate on pump and align bolt holes. 2) Install reverse clutch piston onto rear face of pump. Compress spring seat and install snap ring. Using straightedge and feeler gauge. See Fig. compress reverse clutch spring seat. 12: Checking Oil Pump Gear Clearance Courtesy of Suzuki of America Corp.

To assemble 2nd clutch assembly. input gear should lock in clockwise rotation. Inspection & Reassembly 1) Apply compressed air to piston check ball. check one-way clutch rotation. 3) Using appropriate spring compressor. Note direction of sprag assembly. 3RD CLUTCH ASSEMBLY Disassembly 1) Mount 3rd clutch assembly in soft-jawed vise. reverse disassembly procedure. Ensure air passes in one direction only. 21)1995 Suzuki Si . Once hub assembly is assembled. snap ring and spacer. See Fig. Remove ring gear.HYDRA-MATIC 3L30Article Text (p. Disassemble 3rd clutch hub. 13: Checking 3rd Clutch Hub Rotation Courtesy of Suzuki of America Corp. compress return spring seat and remove snap ring. 2) Using appropriate spring compressor. 8 and 13. Inspection & Reassembly Apply compressed air to piston check ball. Ensure air passes in one direction only. Remove spring seat. Remove spring seat. return springs and piston. Remove clutch plates and discs. Compress retaining ring using several thin blade screwdrivers.1) Remove snap ring from 2nd clutch drum. 2) Remove 3rd clutch hub. To assemble remaining 3rd clutch components. reverse disassembly procedure. 13. 8. See Fig. Insert screwdrivers in slots in drum and push up on inside clutch plate to force snap ring from groove. clutch plates. thrust bearing and washer. compress spring seat and remove snap ring. return springs and piston. Fig. See Figs. AUTO TRANS DIAGNOSIS . Remove bronze thrust washer. 2) Holding hub assembly with input gear facing forward.

85 mm). See Fig.HYDRA-MATIC 3L30Article Text (p. 14.13-. The following procedure applies to Suzuki only. Place current pressure plate on top of stack.035" (. Install thrust washer. 22) . Soak all friction discs and brake band in transmission fluid for at least 15 minutes before reassembly.005-. thrust bearing and low brake drum (planetary rear sun gear) with rear sun gear thrust washer. NOTE: 1) Align tangs of clutch discs in 2nd clutch assembly and install 3rd clutch assembly. 3) Determine correct reverse clutch pressure plate thickness. Replace as needed.PLANETARY GEAR CARRIER Inspection Visually check carrier for distortion and damage. Install brake band. 14: Checking Planetary Gear Pinion Gear Clearance Courtesy of Suzuki of America Corp. check planetary pinion gear clearance. 2) Place thrust bearing and washer on planetary rear sun gear and install planetary gear carrier. Place transmission case facing up. Using Nira Sakhalin R 1995 Suzuki SidekickFor saer AUTO TRANS DIAGNOSIS . Clearance should be . Fig. TRANSMISSION REASSEMBLY NOTE: Ensure correct thrust bearing and washer placement during reassembly. Place thrust washer and bearing into top of planetary carrier. NOTE: Manufacturer does not provide reverse clutch pressure plate thickness specifications for Geo. Using feeler gauge. Insert 2nd/3rd clutch assemblies into case. 15. See Fig. Compress stack by hand. Stack steel and lined plates with spring plate on surface plate.

30-6.27) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Fig. 15: Identifying Transmission Thrust Bearings & Washers Courtesy of Suzuki of America Corp.....286 (6.271-. REVERSE CLUTCH PRESSURE PLATE SELECTION (SUZUKI) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Stack Height In..741-.95-18.... (mm) .718-.718 (18. steel clutch plate. then clutch disc and repeat.....81) (18. see REVERSE CLUTCH PRESSURE PLATE SELECTION (SUZUKI) table... .52) (17.24-18. 4) To determine correct pressure plate.40) (6.98) (7. See Fig. ..88-6.82-19. .750 .730-.. 16..252 .....282-.. Fig.vernier caliper.11) (18..... 16: Measuring Reverse Clutch Stack Height (Suzuki) Courtesy of Suzuki of America Corp..23) .69) (6..275 .729 ... (mm) ...59-6. End with spring cushion plate.741 .. Pressure Plate In....707-.263 ..248-... measure stack height...17-7.259-. Install selected pressure place...53-18. AUTO TRANS D ..

Using feeler gauge...36-.5 N. Install servo piston.... 11) Install lever and select shaft.. . See TORQUE SPECIFICATIONS.. 9) Install servo piston return spring and piston rod into case.... ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ 7) Install reverse clutch... Red ..HYDRA-MATICand connect wiring 1995 Suzuki SidekickFor saer Nira Sakhalin R solenoid with oil pipes. See SELECTIVE THRUST WASHER SELECTION table. Install extension housing or transfer case (as applicable)...59) ..... 24) harness. 18.. 5. Ensure manual valve link is attached to select lever.. Install check ball in case oil passage. Tighten thumb screw... .. compress servo piston assembly and install snap ring. . Ensure adjustment bolt is loose. 17. Install snap ring... Loosen thumb screw and allow plunger to contact thrust face of 2nd clutch housing.. Tighten nut on end of shaft. 8) Install "O" ring on input shaft.. 6.5) Determine correct input shaft thrust washer. 2 3 4 5 6 7 Color ..73-2.. Ensure end play is . 12) Install valve body onto case with new gaskets and separator plate... 13) Install detent roller assembly. Turn adjustment bolt until it contacts band. See Fig...... speedometer drive gear and snap ring..88) (1.26) (2..... oil pump and converter housing assembly..01) (1.79 mm). Blue . . Secure servo piston sleeve with wrench......074 .. tighten adjustment bolt to 40 INCH lbs. Install governor assembly on back end of transmission..41-2.083-... 6) Remove measuring tool.. If end play is not within specification.089 ..... 014-....094 ... SELECTIVE THRUST WASHER SELECTION ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ I.102 Thickness (1..... See TORQUE SPECIFICATIONS.. 10) Adjust brake band..13) (2... Using Servo Compressor (09927-66020 or J-23075).. Inspect input shaft end play. Install TCC AUTO TRANS DIAGNOSIS .. Install ...... Install filter (screen).... Install roll pin in manual select shaft..36-. See Fig.014-..060-...... Install bolts and tighten to specification....39) (2.. Yellow .075-..031" (...11-2....084 . Install oil pressure switch...............031" (.079 .. Green ..52-1... See Fig. Using torque wrench. Natural . See Fig. measure length of plunger protrusion.91-2. (4...79 mm) end play and install..095-.. Place Depth Measuring Tool (09923-46010 or J-23085) on flange of case..... Select appropriate thrust washer to obtain ..068-.. Black .. Install reinforcement plate. select alternate thrust washer and remeasure.m)... Back off adjustment bolt EXACTLY 5 turns and tighten lock nut.. Tighten valve body bolts to specified torque......D No..29-2.. .090-. Install park/neutral position switch. Install 3L30Article Text (p...

83-.83 mm).2 mm).servo cover.33" (30. Fig.67-33. 18: Installing Valve Body Courtesy of Suzuki of America Corp.2-23. Install oil pan with magnets.91" (21. Install oil cooler pipes.21-1. See TORQUE SPECIFICATIONS. 19. Install torque converter. 14) Install kick-down cable. Measure converter installed depth to confirm correct installation. Depth on Tracker should be . AUTO TRANS DIA . Depth on Sidekick should be 1. See Fig. 17: Measuring 2nd Clutch Drum Depth Courtesy of Suzuki of America Corp. Fig. Tighten bolts to specification.

....... Servo Cover Bolt .......... Oil Screen Bolt ...................... 84 (9................m) Brake Band Adjusting Bolt ..........m) Converter-To-Drive Plate Bolt Geo ....................................... Suzuki ...... Suzuki ...................................... Extension Housing-To-Case Bolt ....... Transmission Case-To-Converter Housing Bolt . (N.......................................... 84 Suzuki Oil Pan Bolt .......................... 36 (4..................................... 108 (12......... 19: Measuring Torque Converter Installation Courtesy of Suzuki of America Corp........ (N................................... 26)1995 (9. 35 (48) 47 (65) 15 21 23 14 14 (20) (30) (31) (19) (19) 15 (21) 20 14 18 25 17 14 (27) (19) (25) (34) (23) (19) INCH Lbs. Transfer Case Bolt .....................................................................................HYDRA-MATIC 3L30Article Text (p................. Cooler Union Nut Geo .........Fig............... Selector Lever Nut Geo .............................. Park/Neutral Position Switch Adjusting Bolt .1) AUTO TRANS DIAGNOSIS . Lbs........... TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Ft......... Valve Assembly-To-Case Bolt ........................................................... Suzuki ........2) Oil Pressure Switch ............ Oil Pump-To-Converter Housing Bolt ...5) ....5)SidekickFor saer Nira Sakhalin R Governor Bolt ....

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ WIRING DIAGRAMS Fig. 20: 1995 Transmission Wiring Diagram (Geo Tracker) AUTO TRANS DIAGNOSIS - .

28)1995 Suzuki SidekickFor saer Nira Sakhalin R .Fig.HYDRA-MATIC 3L30Article Text (p.6L) AUTO TRANS DIAGNOSIS . 21: 1995 Transmission Wiring Diagram (Suzuki Sidekick 1.

HYDRA-MATIC 3L30Article Text (p. 22: 1996 Transmission Wiring Diagram (Geo Tracker) AUTO TRANS DIAGNOSIS .Fig. 29)1995 Suzuki SidekickFor saer Nira Sakhalin R .

30)1995 Suzuki SidekickFor saer Nira Sakhalin R .6L) AUTO TRANS DIAGNOSIS .Fig. 23: 1996 Transmission Wiring Diagram (Suzuki Sidekick 1.HYDRA-MATIC 3L30Article Text (p.

31)1995 Suzuki SidekickFor saer Nira Sakhalin R END OF ARTICLE . 24: 1996 Transmission Wiring Diagram (Suzuki Sidekick 1.HYDRA-MATIC 3L30Article Text (p.6L) AUTO TRANS DIAGNOSIS .Fig.

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