03-72LE Transmission Troubleshooting

[Nunapitchuk]

Background: Did complete rebuild of transmission (seals, gaskets, steels, friction plates). Followed all instructions in service manual ('94/'95 supplement manual). I feel very (like 90%) certain that I did not make mistakes. I made a 23 part video of the whole process and posted to my face book page (Suzuki Sidekick Restoration Project) and my U-Tube channel (just look up AW 03-72LE (A44DE) and my videos will come up). So when I put my shiny new transmission in and tried it, well, only reverse worked. No D or 1 or 2. Absolutely nothing in forward gears.

Now there was one thing that bothered me when I put it together and still bothers me. The tube from the middle accumulator to the front side of the oil pan. I will attach photos. All the tubes go in tight holes except this one. It just kind of pokes into a rectangular hole. Makes no sense to me. Then I started thinking, maybe it is suppose to be a hole, but pieces broke off (the transmission was a real mess when I started).

I wonder if you have one around that you could look at (FixKick or any reader) that you could check and compare to mine and then let me know if mine looks normal or broken.

And, finally, if mine is abnormal, could this be the cause of my problem?

I appreciate any help I can get.
Frank.

[fixkick]

for sure that pipe is not right. falls out"?

http://www.fixkick.com/tranny/sidekick_d...manual.pdf

see page 130 pdf and the air pressure tests?


page 143 says one tube is the forward clutch
but it seems to me that is tube 3 in your photo
why are all other tubes missing?

looks like that tube of yours is in the wrong hole or the hole is damaged.
best I can tell
sorry.

[Nunapitchuk]

Thanks for the PDF Fixkick. It is almost identical to my manual, but there are some differences. My manual says that the tube in question is the Brake Applying Tube just like page 143 in your manual. It is confusing because the manual you provided (pg 139) identifies that same tube as the Forward Clutch. My manual does not have that part in it and that would totally explain why I have no forward gears!

I removed the other tubes for the photo so that it would be more clear which I was referencing. The hole has to be damaged like you said. How? I don't know. I will remove valve body and attempt to repair the hole. I think I can weld over it with aluminum rod and then re-drill it to fit the tube. If not, then I will have to wait for the snow to melt off of my parts car so I can get the transmission out of it.

In any case, as usual, you have been very helpful. Thank you.
Frank.

[fixkick]

my guess , car that had this, was high centered, on rock (crawling) and bashed the pan then hit the tube, and what you got was 1/2 way fixed box. (this part)

did you test the box with the TCM unplugged, doing the manual mode test./? Im sure you did.

all tubes shown but not labeled.
https://www.transpartsonline.com/TRANS_P...tsType=A40

wish there was hydraulic schematic map like the 3speed TH180 has,

i see the old A44D (no E) has only 2 tubes.

here is the Suzuki parts list that decodes this, in a few minutes, ........ bingo

[fixkick]

this is out off the official Suzuki book on parts, 92-98, 4speed Electric shifted box. (TCM brain)

so its 28, seems to me.
sorry for your grief finding damage hard to fix.

TIG and reDrill. hope.

[Nunapitchuk]

Yes, it is tube labeled 28 (forward clutch). I could not get my weld to stick, don't have actual TIG (yet). I took the valve body out and got a closer look at the opening. Looking at it, I just don't really see signs of damage. Really, it looks like it was made this way -- hence my confusion.

Oil pan in good condition (could have been replaced). The torque converter has "1995 Suzuki Sidekick" written on in with some kind of marker so I am pretty sure that the transmission has been removed before I owned it. It was not in running condition when I bought it so I have never done any testing like the manual shift test. When I tested this transmission was the first time I have started the car (my engine rebuild seems to be running good). Reverse worked, but no forward anything so I know the torque converter, oil pump, manual shift valve, and solenoid valves are working.

When I was putting it back together I did all the air pressure tests except for the forward clutch. I skipped that because I could not blow air in the specified hole (the one in question). All others were good. I thought it was strange, but it is my first transmission rebuild so I just thought "that is weird" and stuck the tube in the rectangular opening. I see on my video review that I had some trouble with that same tube when I was trying to get the oil pan back on.

Right now I put J-B weld on it. Completely covered the rectangular opening. When it is done curing today I will see if I can drill a round hole for the tube to fit. I have another transmission, but it is on my parts car outside buried in the snow. It is too close to spring to dig it out. Better just wait a month for the snow to melt if I decide to pull that one out.

[Nunapitchuk]

Update: I just got a photo of another transmission from a face book friend that shows the way that hole is suppose to look. There is suppose to be a thin layer of aluminum with a round hole just as I suspected. Mine was definitely broken out. Seems so dumb that I overlooked it the first time. Oh well. If I didn't say it enough already, Thank you for the help with my project. If the JB Weld works then I will be ready for a test drive by the end of the month (been working on it for 3 winters!). Yippy.

[fixkick]

make sure its there high temp brand
or

https://www.autozone.com/sealants-glues-...515553_0_0