1995 AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30

[Whitfield]

http://www.suzukioffroad.com.br/tecnica//S_at2%20-%20Automatic%20Transmissions%203L30%20Sidekick%20and%20Tracker.pdf



Original text has diagrams

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
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Vehicle Labor Times Trans.
Application (1) R & I (2) Overhaul Model
Geo
1995-96 Tracker
2WD .................. 4.8 ......... 7.1 ......... 3L30
4WD .................. 5.8 ......... 7.1 ......... 3L30
Suzuki
1995-96 Sidekick
2WD .................. 4.8 ......... 7.1 ......... 3L30
4WD .................. 5.8 ......... 7.1 ......... 3L30
(1) - Removal and installation of transmission from vehicle
chassis.
(2) - Bench overhaul time for transmission. DOES NOT include
removal and installation.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
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.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 2)1995 Suzuki Sidekick
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 section.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 3)
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 and/or cut turbine shaft "O" ring.
No Vehicle Movement In Any Range
Check fluid level, clogged oil pump screen, disconnected
manual valve link or manual select shaft inner lever, broken input
shaft, pressure regulator valve stuck in open position or faulty oil
pump.
No Vehicle Movement In Any Gear Position
Check for parking pawl disengagement.
Vehicle Movement Under RPM Increase Only
Check for stuck servo piston, low fluid level, faulty oil
pump, missing oil pump screen or missing valve body sealing ball
(plug).
Heavy Jerking During Initial Vehicle Movement
Check for low fluid pressure, incorrect modulator valve,
stuck pressure regulator valve or missing valve body sealing ball
(plug).
No Vehicle Movement In "D" Or "2", Vehicle Moves In "L" Or
"R"
Input sprag installed backwards or sprag failure.
No Movement In "R" Only
Check for reverse clutch failure.
Vehicle Movement In Neutral Position
Check for improperly adjusted shift selector cable, broken
planetary gear carrier and/or low band adjustment.
No 1-2 Upshift
Check for stuck governor valves, 1-2 shift valve stuck in 1st
position, leaking oil pump seal rings, leak in governor pressure
circuit and/or clogged governor oil screen.
No 2-3 Upshift
Check for stuck 2-3 shift valve and/or leak in governor
pressure circuit.
Upshifting Under Full Throttle Only
Check for faulty modulator, leaking modulator vacuum line,
engine vacuum leak and/or stuck kick-down valve or cable.
Upshifting Under Part Throttle Only
Check for stuck kick-down pressure regulator valve and/or
misadjusted kick-down cable.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 5)
Vehicle Movement In "1", No Vehicle Movement In "2" Or "R"
1st and reverse control valve stuck in 1st or "R" position.
No Part Throttle 3-2 Downshift At Low Vehicle Speeds
Check 3-2 downshift control valve.
No Forced Downshift
Check kick-down cable adjustment and kick-down pressure
regulator valve.
Transmission Immediately Shifts Into Lower Gear Once Throttle
Is Eased After Full Throttle Upshifting
Check for kick-down valve stuck in open position, stuck kickdown
cable and/or spliced modulator vacuum line.
Transmission Shifts Into Lower Gear At Higher Speeds
Manual select shaft spring pin dropped out, loose connection
at manual valve or pressure loss at governor.
Hard Disengagement Of Select Lever From "P" Position
Missing parking lock actuator guide bushing or stuck manual
select shaft.
Engine Flare, 1-2 Shift
Check for low fluid pressure, missing valve body sealing ball
(plug), leaking 2nd clutch piston seals, 2nd clutch piston check ball
stuck open, broken or cracked 2nd clutch piston, 2nd clutch piston
plates worn or leaking oil pump hub sealing rings.
Engine Flare, 2-3 Shift
Check for low fluid pressure, low band adjustment, missing
valve body sealing ball (plug), leaking 3rd clutch piston seals, 3rd
clutch piston check ball stuck open, broken or cracked 3rd clutch
piston and/or worn input shaft bushing.
Harsh 1-2 Shift
Check for high fluid pressure, stuck 1-2 accumulator valve
and/or broken 2nd clutch spring cushion.
Harsh 2-3 Shift
Check for high fluid pressure or incorrect low band
adjustment.
Harsh 3-2 Manual Downshift
Check for stuck open high speed downshift valve and low band
adjustment.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 6)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Harsh 3-2 Coasting Downshift
Check for stuck open low speed downshift timing valve.
High Speed Downshift Flare
Check for low fluid pressure or low band adjustment
Low Speed Forced Downshift Flare
Check for low fluid pressure, low band adjustment, closed
high speed downshift timing valve and/or one-way clutch does not lock
on 3-1 downshifting.
No Engine Braking In Low
Check select cable adjustment and/or stuck manual low control
valve.
No Engine Braking In "2" Range
Check select cable adjustment.
Transmission Does Not Hold In Park
Improperly adjusted select cable, 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, loose
planetary carrier lock plate, defective thrust bearing, worn bushings
or loose converter housing bolt contacting torque converter.
Screeching Noise When Starting
Torque converter failure.
Short Vibrating, Hissing Noise Shortly Before 1-2 Upshift
Reverse clutch spring cushion wearing into transmission case.
Buzzing Noise
Clogged oil pump screen.
TRANSMISSION COMPONENT APPLICATION CHART
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Selector Lever Position Elements In Use
"D" (Drive)
1st Gear ..................... One-Way Clutch & Low Band
2nd Gear ......................... 2nd Clutch & Low Band
3rd Gear ........................ 2nd Clutch, 3rd Clutch
& One-Way Clutch
"2" (Intermediate)
1st Gear ..................... One-Way Clutch & Low Band
2nd Gear ......................... 2nd Clutch & Low Band
AUTO TRANS DIAGNOSIS - "L" (1st Gear) ................ 3rd Clutch, One-Way Clutch
& Low Band
"R" (Reverse) ................. Reverse Clutch, 3rd Clutch
& One-Way Clutch
"N" (Neutral) ............................. One-Way Clutch
"P" (Park) ................................ One-Way Clutch
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ELECTRONIC TESTING
TORQUE CONVERTER CLUTCH (TCC)
NOTE: Before performing the following procedures, connect a scan
tool to Data Link Connector (DLC) and retrieve any stored
Diagnostic Trouble Codes (DTCs). Repair any engine
performance-related DTCs first. On Geo, a DTC P0740
identifies a TCC electrical circuit malfunction. On Suzuki,
a DTC P0740 or P0770 identifies a TCC solenoid malfunction.
Check for blown fuses and repair short(s) to ground if
necessary. See appropriate wiring diagram in WIRING DIAGRAMS
to aid in component, wire color and terminal identification.
1) Ensure ignition is off. Access Powertrain Control Module
(PCM), located under left side of instrument panel, near kick panel.
Disconnect PCM 22-pin harness connector (C2 on Geo or E34 on Suzuki).
2) Turn ignition on. Using a voltmeter, measure voltage
between ground and PCM harness connector C2 or E34, terminal No. 16
(White/Yellow wire). If battery voltage is present, go to next step.
If battery voltage is not present, check TCC relay. See
TORQUE CONVERTER CLUTCH (TCC) RELAY. Replace if necessary. If relay is
okay, go to step 4).
3) Start engine and allow it to reach normal operating
temperature. Raise and support vehicle to allow rear wheels to spin
freely. Shift selector lever to "D" position and accelerate. If
voltage reading decreases to 0-1 volt at about 47 MPH, check TCC
relay. See TORQUE CONVERTER CLUTCH (TCC) RELAY. Replace if necessary.
If relay is okay, go to step 6). If voltage reading is not as
specified, go to step 5).
4) Check for poor TCC relay harness connection. Check
White/Yellow wire between TCC relay and PCM for an open or short to
ground. Check Blue/Black wire between TCC relay and main relay for an
open or short to ground. Repair as necessary. If no problems are
found, substitute a known-good PCM and retest system.
5) Check for poor harness connections at PCM. Repair as
necessary. If no problems are found, substitute a known-good PCM and
retest system.
6) Turn ignition off. Disconnect TCC relay. Turn ignition on.
AUTO TRANS Using a voltmeter, measure voltage between ground and TCC relay
harness connector terminal No. 2 (Black/White wire). If reading is
battery voltage, go to next step. If reading is not as specified,
repair open in Black/White wire.
7) Check TCC solenoid. See
TORQUE CONVERTER CLUTCH (TCC) SOLENOID. Replace if necessary. If
solenoid is okay, go to next step.
Check White wire between TCC relay and TCC solenoid for an
open or poor connection. Repair as necessary. If no problem is found,
check for low fluid pressure, misadjusted kick-down cable or other
internal transmission problems.
TORQUE CONVERTER CLUTCH (TCC) RELAY
1) Turn ignition off. Remove TCC relay. Using an ohmmeter,
measure resistance between relay terminals No. 1 and 3. See Fig. 2.
Resistance should be 90-110 ohms. Continuity should not be present
between terminals No. 2 and 4.
2) Apply battery voltage to terminal No. 1, and ground
terminal No. 3. Continuity should now be present between terminals No.
2 and 4. Replace relay if it does not test as specified.
Fig. 2: Identifying TCC Relay Terminals
Courtesy of Suzuki of America Corp.
TORQUE CONVERTER CLUTCH (TCC) SOLENOID
1) Remove TCC solenoid from transmission. Using Orifice Plug
(09922-85811), plug one oil passage on TCC solenoid. Using an oiler,
add ATF to remaining oil passage. See Fig. 3. Oil should exhaust from
solenoid.
2) Using fused jumper wires, apply battery voltage and ground
to TCC solenoid terminals. Solenoid should click and not allow any oil
to exhaust. Replace TCC solenoid if it does not test as specified.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 9)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 3: Testing TCC Solenoid
Courtesy of Suzuki of America Corp.
TESTING
TIME LAG TEST
1) Engine and transmission must be at normal operating
temperature. Start engine and ensure idle RPM is within specification
with A/C off. Apply service and parking brakes. Using stop watch,
measure time until engagement shock is felt when selector lever is
shifted from "N" to "D" position.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 2) Allow one minute intervals between tests. Perform time
measurements 2 more times and calculate average value. Time should be
less than 1.2 seconds. Repeat test procedure to test time lag when
selector lever is shifted from "N" to "R" position. Time lag should be
less than 1.5 seconds. If results are not within specification,
inspect internal components.
ROAD TEST
1) Ensure vehicle is at operating temperature. Shift
transmission into drive. Accelerate vehicle and ensure vehicle
upshifts from 1st to 2nd, then to 3rd gear. TCC should apply while in
3rd gear.
2) Depress accelerator pedal to 1/2 position. TCC should
release, then transmission should downshift to 2nd gear. Accelerate to
cruising speed until TCC is applied. Using left foot, very lightly
apply brake pedal. TCC should disengage.
3) Release accelerator pedal. As vehicle is slowing down,
manually shift into 2nd gear, then into low position. Ensure
transmission shifts into lower gears and engine braking occurs. Stop
vehicle and shift into reverse. Lightly accelerate vehicle to confirm
reverse operation. Stop vehicle on slight incline. Shift vehicle into
park. Ensure vehicle does not move.
HYDRAULIC PRESSURE TESTS
Line Pressure Test
1) Ensure transmission fluid is at normal operating
temperature. Raise and support vehicle. Place a wood block between
distributor housing and firewall to prevent damage to distributor cap
when lowering transmission.
2) Support transmission with jack. Unbolt cross member and
lower transmission to gain access to pressure port. Connect
appropriate pressure gauge to line pressure test port on transmission.
See Fig. 4.
3) Apply service brake and shift transmission to "D"
position. Release brake and allow wheels to accelerate to
approximately 28 MPH. Allow engine to idle (approximately 1500 RPM).
Check line pressure and record pressure reading. Repeat test in "2"
and "L" position.
4) Apply brakes. Shift transmission to "D" position.
Disconnect modulator vacuum line. Depress accelerator pedal to Wide
Open Throttle (WOT). Do not hold engine at WOT for more than 5
seconds. Check line pressure and record pressure reading. Repeat test
in "2" and "L" position. See LINE PRESSURE SPECIFICATIONS table.
LINE PRESSURE SPECIFICATIONS
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
AUTO TRANS DIAGNOSIS - Shifter Position psi (kg/cmý)
Idle Speed
Geo
"D" & "2" .................................... 65 (4.6)
"L" .......................................... 95 (6.7)
Suzuki
"D" & "2" ............................. 54-63 (3.8-4.5)
"L" .................................. 87-102 (6.1-7.1)
WOT
Geo
"D" & "2" ................................... 118 (8.3)
"L" ........................................ 160 (11.2)
Suzuki
"D" & "2" ........................... 100-112 (7.0-7.9)
"L" ............................... 161-177 (11.3-12.4)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Fig. 4: Identifying Pressure Test Port
Courtesy of Suzuki of America Corp.
VACUUM MODULATOR
NOTE: A faulty vacuum modulator can cause:
* Harsh upshift and downshifts.
* Delayed upshifts.
* Soft upshifts and downshifts.
* Slips in "L", "D" and "R".
* Transmission overheating.
* Burnt transmission fluid.
1) Remove modulator. Hold modulator so vacuum fitting points
downward. Replace modulator if full of transmission fluid.
AUTO TRANS DIAGNOSIS - HYDRA-2) Connect vacuum pump. Apply 20 In. Hg of vacuum. Ensure
modulator operates and holds vacuum. Replace if necessary.
ON-VEHICLE SERVICE
EXTENSION HOUSING & GOVERNOR ASSEMBLY
Removal
1) Raise and support vehicle. Place reference marks on drive
shaft and companion flange. Remove drive shaft, speedometer cable and
speedometer driven gear. Support transmission with jack. Remove
transmission-to-cross-member bolts and rear mount from extension
housing.
2) Remove extension housing bolts and remove extension
housing. Note bolt length and location. On 4WD vehicles, remove
transfer case and adaptor. See appropriate article in AXLE SHAFTS &
TRANSFER CASES section.
3) Remove snap ring, speedometer drive gear and remaining
snap ring from output shaft. Remove governor assembly (if applicable).
Installation To install, reverse removal procedure. Ensure
output shaft bolt hole is aligned with governor assembly. Install
extension housing and new gasket. Clean all bolt threads.
SHIFT LINKAGE
For shift linkage adjustment, see ADJUSTMENTS in appropriate
AUTOMATIC TRANSMISSION SERVICING article.
KICKDOWN CABLE/THROTTLE CABLE
For kickdown or throttle cable adjustment, see ADJUSTMENTS in
appropriate AUTOMATIC TRANSMISSION SERVICING article.
REMOVAL & INSTALLATION
For transmission removal and installation procedure, see
REMOVAL & INSTALLATION in appropriate AUTOMATIC TRANSMISSION REMOVAL
article.
TORQUE CONVERTER
NOTE: Torque converter is a sealed unit and must be serviced as a
complete assembly. Perform the following tests to check
torque converter condition. Torque converter and
transmission cooler must be thoroughly cleaned and flushed
if transmission fluid is contaminated.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 13)1995 Suzuki SidekickFor saer Nira Sakhalin Russia STATOR (ONE-WAY CLUTCH) TEST
Insert finger into splined inner race of roller clutch and
try to turn race in both directions. Clutch should lock when rotated
counterclockwise, and turn freely when rotated clockwise. Replace
torque converter if clutch fails test.

[Whitfield]

TRANSMISSION DISASSEMBLY
1) Remove oil pan and filter. Remove manual detent roller
assembly. Remove TCC solenoid and harness assembly. Remove governor
pressure switch from valve body. Remove reinforcement plate under TCC
solenoid. Remove servo cover.
2) Unbolt and remove valve body with manual valve, link,
separator plate and gaskets. Remove check ball in transmission case.
See Fig. 5. Using Servo Compressor (09927-66020 or J-23075), compress
servo piston assembly and remove snap ring. See Fig. 6.
3) Remove compressor. Remove servo assembly with spring and
rod. Remove Park/Neutral Position (PNP) switch. Pull roll pin from
manual select shaft. Place a metal plate between manual select shaft
inner lever and case. Loosen nut on end of shaft and remove. Remove
lever and select shaft.
4) Remove extension housing or transfer case. Remove
modulator and modulator plunger. Remove roll pin from kickdown valve
sleeve. Remove remaining kickdown valve components. See Fig. 7. Remove
speedometer gear retaining snap ring, gear and snap ring.
5) Remove governor hub. Remove governor from hub. Remove
small filter screen from hub. See Fig. 8. Remove "O" ring from input
shaft. Remove bolts securing converter housing to transmission case.
6) Remove housing, oil pump and reverse clutch piston as
complete assembly. Remove 2nd and 3rd clutch assemblies. See Fig. 8.
Remove remaining reverse clutch plate and pressure plate.
7) Remove planetary gear. Remove thrust bearing from top of
sun gear if bearing did not stay with planetary gear. Remove rear sun
gear assembly. Remove low brake band and any remaining thrust bearing
and washer.
Remove manual select shaft inner lever and parking lock
actuator assembly. Separate 2nd clutch from 3rd clutch. Remove
electrical harness connector.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 14)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 5: Locating Transmission Case Check Ball
Courtesy of Suzuki of America Corp.
Fig. 6: Compressing Servo Piston Assembly
Courtesy of Suzuki of America Corp.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 15)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 7: Exploded View Of Modulator & Kick-Down Assemblies
Courtesy of Suzuki of America Corp.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 16)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 8: Exploded View Of Transmission Assembly
Courtesy of Suzuki of America Corp.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 17)1995 Suzuki SidekickFor saer Nira Sakhalin Russia COMPONENT DISASSEMBLY & REASSEMBLY
GOVERNOR BODY
Disassembly & Reassembly
Depress secondary valve spring and remove secondary valve
spring retainer. See Fig. 9. Remove components from governor body.
Inspect valves for scoring, nicks or burrs. Polish with crocus cloth.
To assemble, reverse disassembly procedures. Ensure valves move
freely.
Fig. 9: Exploded View Of Governor Assembly
Courtesy of Suzuki of America Corp.
VALVE BODY ASSEMBLY
NOTE: All valve body components must be installed in original
location. Lay all components in sequence during removal for
reassembly reference.
Disassembly
Remove manual valve. Individually remove each valve retaining
pins. Remove all components. See Fig. 10.
Inspection
Clean all parts in solvent. Dry with compressed air. Ensure
all valve body passages are clear. Inspect valves for scoring or
roughness. Ensure valves slide freely in bores. Inspect valve springs
for damage, squareness and collapsed coils. Measure spring free length
and outer diameter. Replace spring if not within specification. See
appropriate VALVE BODY SPRING SPECIFICATIONS table.
VALVE BODY SPRING SPECIFICATIONS (GEO)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Diameter Free Length
Description In. (mm) In. (mm) Color
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 18)1995 Suzuki SidekickFor saer Nira Sakhalin Russia 1-2 Shift Control
Valve ................... (1) ......... (1) .............. (1)
1-2 Shift Valve ....... .750 (19.1) .. 2.438 (61.9) ........ (1)
2-3 Shift Control
Valve ............... .687 (17.4) .. 1.750 (44.5) ........ (1)
3-2 Control Valve ..... .438 (11.1) .. 1.750 (44.5) ........ (1)
Detent Pressure
Regulator ........... .500 (12.7) .. 1.625 (41.3) ........ (1)
High Speed Downshift
Valve ............... .438 (11.1) .. 1.313 (33.4) ........ (1)
Low Speed Downshift
Valve ............... .438 (11.1) .. 1.375 (34.9) ........ (1)
Low Reverse Control
Valve ............... .438 (11.1) .. 1.313 (33.4) ........ (1)
1-2 Accumulator
Valve ............... .500 (12.7) .. 1.063 (27.0) ........ (1)
(1) - Information not available from manufacturer.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
VALVE BODY SPRING SPECIFICATIONS (SUZUKI)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Diameter Free Length
Description In. (mm) In. (mm) Color
1-2 Shift Control
Valve ................ .31 ( .... .53 (13.5) ......... Black
1-2 Shift Valve ...... .72 (18.3) ... 2.46 (62.5) ..... Lt. Blue
2-3 Shift Control
Valve .............. .72 (18.3) .... 2.13 (54) .. Brown/Yellow
3-2 Control Valve .... .41 (10.3) .... 1.61 (41) ........ Silver
Detent Pressure
Regulator ........... .47 (12) ..... 1.57 (40) .. Yellow/Green
High Speed Downshift
Valve ............... .48 (12.2) .. 1.31 (33.2) .... Blue/Pink
Low Speed Downshift
Valve ............... .4 (10.3) .... 1.30 (33) .... Blue/Green
Low Reverse Control
Valve ............... .4 (10.3) .... 1.34 (34) ... Light Green
1-2 Accumulator
Valve ............... .52 (13.3) ... .67 (17) ... Green/Yellow
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Reassembly
Install valves, springs, plugs and retaining pins in proper
order and location. Use a liberal amount of transmission fluid. Ensure
valves move freely and snap back when moved.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 19)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 10: Exploded View Of Valve Body Assembly
Courtesy Of Suzuki of America Corp.
SERVO PISTON ASSEMBLY
Disassembly & Reassembly
Loosen adjusting stud nut and remove. Compress piston and
remove clip. See Fig. 11. Clean all parts and inspect for wear or
damage. To reassemble, reverse disassembly procedure.
Fig. 11: Exploded View Of Servo Piston Assembly
Courtesy of Suzuki of America Corp.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 20)1995 Suzuki SidekickFor saer Nira Sakhalin Russia CONVERTER HOUSING, OIL PUMP & REVERSE CLUTCH ASSEMBLY
Disassembly
1) Remove selective thrust washer from oil pump shaft (if
necessary). Remove bolts and separate converter housing from oil pump.
Remove pump wear plate. Mark pump gears with reference marks and
remove gears.
2) Using appropriate compressor, compress reverse clutch
spring seat. Remove snap ring. Remove reverse clutch piston. See
Fig. 8. If necessary, remove valve assemblies from oil pump by
removing retaining pins.
Inspection
Clean all components in solvent. Inspect valves and valve
bores for scoring, burrs and nicks. Polish valves with crocus cloth
(as needed). Using straightedge and feeler gauge, inspect pump to gear
clearance. See Fig. 12. Clearance should be .0005-.0032" (.02-.08 mm).
Reassembly
1) Place wear plate on pump and align bolt holes. Install NEW
oil seal in converter housing. Place converter housing on oil pump.
Loosely install bolts. Install oil pump Aligning Sleeve (09927-66010
or J-23082-01) through converter housing into pump. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
2) Install reverse clutch piston onto rear face of pump.
Place springs onto piston. Install spring seat. Compress spring seat
and install snap ring.
Fig. 12: Checking Oil Pump Gear Clearance
Courtesy of Suzuki of America Corp.
2ND CLUTCH ASSEMBLY
Disassembly
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 21)1995 Suzuki Sidekick
1) Remove snap ring from 2nd clutch drum. Remove ring gear,
snap ring and spacer. See Fig. 8. Remove clutch plates and discs.
Remove bronze thrust washer.
2) Using appropriate spring compressor, compress spring seat
and remove snap ring. Remove spring seat, return springs and piston.
Inspection & Reassembly
Apply compressed air to piston check ball. Ensure air passes
in one direction only. To assemble 2nd clutch assembly, reverse
disassembly procedure.
3RD CLUTCH ASSEMBLY
Disassembly
1) Mount 3rd clutch assembly in soft-jawed vise. Compress
retaining ring using several thin blade screwdrivers. Insert
screwdrivers in slots in drum and push up on inside clutch plate to
force snap ring from groove.
2) Remove 3rd clutch hub, clutch plates, thrust bearing and
washer. See Figs. 8 and 13. Disassemble 3rd clutch hub. Note direction
of sprag assembly.
3) Using appropriate spring compressor, compress return
spring seat and remove snap ring. Remove spring seat, return springs
and piston.
Inspection & Reassembly
1) Apply compressed air to piston check ball. Ensure air
passes in one direction only. Once hub assembly is assembled, check
one-way clutch rotation.
2) Holding hub assembly with input gear facing forward, input
gear should lock in clockwise rotation. See Fig. 13. To assemble
remaining 3rd clutch components, reverse disassembly procedure.
Fig. 13: Checking 3rd Clutch Hub Rotation
Courtesy of Suzuki of America Corp.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 22)1995 Suzuki SidekickFor saer Nira Sakhalin Russia PLANETARY GEAR CARRIER
Inspection
Visually check carrier for distortion and damage. Using
feeler gauge, check planetary pinion gear clearance. See Fig. 14.
Clearance should be .005-.035" (.13-.85 mm). Replace as needed.
Fig. 14: Checking Planetary Gear Pinion Gear Clearance
Courtesy of Suzuki of America Corp.
TRANSMISSION REASSEMBLY
NOTE: Ensure correct thrust bearing and washer placement during
reassembly. See Fig. 15.
NOTE: Soak all friction discs and brake band in transmission fluid
for at least 15 minutes before reassembly.
1) Align tangs of clutch discs in 2nd clutch assembly and
install 3rd clutch assembly. Place transmission case facing up.
Install brake band. Install thrust washer, thrust bearing and low
brake drum (planetary rear sun gear) with rear sun gear thrust washer.
2) Place thrust bearing and washer on planetary rear sun gear
and install planetary gear carrier. Place thrust washer and bearing
into top of planetary carrier. Insert 2nd/3rd clutch assemblies into
case.
NOTE: Manufacturer does not provide reverse clutch pressure plate
thickness specifications for Geo. The following procedure
applies to Suzuki only.
3) Determine correct reverse clutch pressure plate thickness.
Stack steel and lined plates with spring plate on surface plate. Place
current pressure plate on top of stack. Compress stack by hand. Using
AUTO TRANS DIAGNOSIS vernier caliper, measure stack height. See Fig. 16.
4) To determine correct pressure plate, see REVERSE CLUTCH
PRESSURE PLATE SELECTION (SUZUKI) table. Install selected pressure
place, steel clutch plate, then clutch disc and repeat. End with
spring cushion plate.
REVERSE CLUTCH PRESSURE PLATE SELECTION (SUZUKI)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Stack Height Pressure Plate
In. (mm) In. (mm)
.741-.750 (18.82-19.11) ............ .248-.252 (6.30-6.40)
.730-.741 (18.53-18.81) ............ .259-.263 (6.59-6.69)
.718-.729 (18.24-18.52) ............ .271-.275 (6.88-6.98)
.707-.718 (17.95-18.23) ............ .282-.286 (7.17-7.27)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Fig. 15: Identifying Transmission Thrust Bearings & Washers
Courtesy of Suzuki of America Corp.
Fig. 16: Measuring Reverse Clutch Stack Height (Suzuki)
Courtesy of Suzuki of America Corp.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 24)1995 Suzuki SidekickFor saer Nira Sakhalin Russia 5) Determine correct input shaft thrust washer. Place Depth
Measuring Tool (09923-46010 or J-23085) on flange of case. See
Fig. 17. Loosen thumb screw and allow plunger to contact thrust face
of 2nd clutch housing. Tighten thumb screw.
6) Remove measuring tool. Using feeler gauge, measure length
of plunger protrusion. Select appropriate thrust washer to obtain .
014-.031" (.36-.79 mm) end play and install. See SELECTIVE THRUST
WASHER SELECTION table.
SELECTIVE THRUST WASHER SELECTION
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
I.D No. Color Thickness
2 .................. Yellow ...... .060-.074 (1.52-1.88)
3 .................. Red ......... .068-.079 (1.73-2.01)
4 .................. Black ....... .075-.084 (1.91-2.13)
5 ................. Natural ...... .083-.089 (2.11-2.26)
6 ................. Green ........ .090-.094 (2.29-2.39)
7 .................. Blue ........ .095-.102 (2.41-2.59)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
7) Install reverse clutch, oil pump and converter housing
assembly. Install bolts and tighten to specification. See
TORQUE SPECIFICATIONS. Inspect input shaft end play. Ensure end play
is .014-.031" (.36-.79 mm). If end play is not within specification,
select alternate thrust washer and remeasure.
Install "O" ring on input shaft. Install governor assembly
on back end of transmission. Install snap ring, speedometer drive gear
and snap ring. Install extension housing or transfer case (as
applicable).
9) Install servo piston return spring and piston rod into
case. Install servo piston. Ensure adjustment bolt is loose. Using
Servo Compressor (09927-66020 or J-23075), compress servo piston
assembly and install snap ring. See Fig. 6.
10) Adjust brake band. Secure servo piston sleeve with
wrench. Turn adjustment bolt until it contacts band. Using torque
wrench, tighten adjustment bolt to 40 INCH lbs. (4.5 N.m). Back off
adjustment bolt EXACTLY 5 turns and tighten lock nut.
11) Install lever and select shaft. Tighten nut on end of
shaft. Install roll pin in manual select shaft. Install park/neutral
position switch. Install check ball in case oil passage. See Fig. 5.
12) Install valve body onto case with new gaskets and
separator plate. Ensure manual valve link is attached to select lever.
Tighten valve body bolts to specified torque. See TORQUE
SPECIFICATIONS. See Fig. 18.
13) Install detent roller assembly. Install filter (screen).
Install reinforcement plate. Install oil pressure switch. Install TCC
solenoid with oil pipes. Install and connect wiring harness. Install
AUTO TRANS DIAGNOSIS servo cover.
14) Install kick-down cable. Install oil pan with magnets.
Install oil cooler pipes. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Install torque converter. Measure converter
installed depth to confirm correct installation. See Fig. 19. Depth on
Sidekick should be 1.21-1.33" (30.67-33.83 mm). Depth on Tracker
should be .83-.91" (21.2-23.2 mm).
Fig. 17: Measuring 2nd Clutch Drum Depth
Courtesy of Suzuki of America Corp.
Fig. 18: Installing Valve Body
Courtesy of Suzuki of America Corp.
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 26)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 19: Measuring Torque Converter Installation
Courtesy of Suzuki of America Corp.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application Ft. Lbs. (N.m)
Converter-To-Drive Plate Bolt
Geo ............................................ 35 (48)
Suzuki ......................................... 47 (65)
Cooler Union Nut
Geo ............................................ 15 (20)
Suzuki ......................................... 21 (30)
Extension Housing-To-Case Bolt ................... 23 (31)
Oil Pump-To-Converter Housing Bolt ............... 14 (19)
Oil Screen Bolt .................................. 14 (19)
Park/Neutral Position Switch
Adjusting Bolt ................................. 15 (21)
Selector Lever Nut
Geo ............................................ 20 (27)
Suzuki ......................................... 14 (19)
Servo Cover Bolt ................................. 18 (25)
Transmission Case-To-Converter Housing Bolt ...... 25 (34)
Transfer Case Bolt ............................... 17 (23)
Valve Assembly-To-Case Bolt ...................... 14 (19)
INCH Lbs. (N.m)
Brake Band Adjusting Bolt ....................... 36 (4.1)
Governor Bolt ................................... 84 (9.5)
Oil Pan Bolt .................................. 108 (12.2)
Oil Pressure Switch ............................. 84 (9.5)
AUTO TRANS DIAGNOSIS - ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
WIRING DIAGRAMS
Fig. 20: 1995 Transmission Wiring Diagram (Geo Tracker)
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 28)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 21: 1995 Transmission Wiring Diagram (Suzuki Sidekick 1.6L)
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 29)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 22: 1996 Transmission Wiring Diagram (Geo Tracker)
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 30)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 23: 1996 Transmission Wiring Diagram (Suzuki Sidekick 1.6L)
AUTO TRANS DIAGNOSIS - HYDRA-MATIC 3L30Article Text (p. 31)1995 Suzuki SidekickFor saer Nira Sakhalin Russia Fig. 24: 1996 Transmission Wiring Diagram (Suzuki Sidekick 1.6L)
END OF ARTICLE

[slowmotion4x4]

Wow. a lot of great info there. I am printing this for future reference 
Thanks for the post

[bentparts]

Uh, I missed that, could you repeat it?