TW-40LS Transmission Master Rebuild Kit Suzuki Every

Imported kei vans and mini 4x4s are on American roads in growing numbers, and when the automatic in a Suzuki Every or Jimny starts slipping, local parts counters usually have nothing for it. This master rebuild package is built for the TW-40L and TW-40LS four-speed automatic: one overhaul kit with the gaskets and seals, one complete friction plate set and one complete steel plate set, sold together so a teardown has every wear part in hand before the case is split. Reference numbers on the set are T20002C, T200080C and T200081C.

What the master kit does in a TW-40LS

The TW-40 family is a compact Aisin four-speed for rear-drive and four-wheel-drive vehicles with small engines, rated for roughly 120 Nm of engine torque. It was known as the A174 until about 2003, and the LE and LS letters mark later variants. In a 2005 Jimny 1.3 the gears run 2.875 first, 1.568 second, 1.000 third and 0.696 overdrive, with a 2.300 reverse, so each upshift is a big step and a worn clutch shows up quickly as a flare or a slip. Inside, small multi-plate clutch packs apply each range, and every piston relies on rubber seals and sealing rings to hold pressure. This kit renews all of the friction facings, the steel plates they run against, and the full set of seals, O-rings and gaskets that keep the oil where it belongs.

Symptoms that mean it is time to rebuild

• Engine revs climb on the 1-2 or 2-3 shift before the gear takes hold
• Long delay engaging Drive or Reverse, especially when cold
• Slipping on hills or when climbing in four-wheel drive under load
• Dark, burnt-smelling fluid with fine friction material in the pan
• Fluid weeping from the pan, case joints or front seal

How to confirm it before you buy

Check fluid level with the engine running and the fluid warm, then look at its color and smell. A unit that is merely low can behave like a worn one. Road test it and note which shift misbehaves and whether it changes as the fluid heats up. Our transmission slipping diagnosis guide covers the checks, and rebuild vs replace vs reman helps decide whether an overhaul makes sense on a small import where used units are hard to find.

Fitment

The listing documents the Suzuki Every 0.7L 2004-2010, Suzuki Jimny 0.7L and 1.3L 2005-2015, Mitsubishi Minicab Van 0.7L 2014, Nissan A-Van 0.7L 2013-2016, Ford Pronto 1.0L 2000-2007, Varica 1.2L 2000-2004 and Veryca 1.2L 2001-2016. The Ford Pronto sold in Taiwan from late 1999 was a locally built version of the tenth-generation Suzuki Carry with a 1.0-liter engine. Be careful with early Every vans: published specs for the 1999-2005 Every list a three-speed automatic, so an older van may not have this four-speed at all. Read the TW-40L or TW-40LS stamp on the case or the ID tag and count the plates in each drum against the kit before discarding the old parts. Not sure what you have? Send us the chassis number and year. More kits are in rebuild kits.

Install notes

• Strip the unit to bare hard parts, clean the case and valve body, and inspect drums, planetary gears, bushings and thrust washers before ordering anything else.
• Soak the new frictions in clean fluid before assembly, and compress the piston return springs with a clutch spring compressor rather than a screwdriver.
• Good snap ring pliers make the small retaining rings much easier to handle without bending them.
• Air-check each clutch circuit, then measure endplay; our guide to thrust washers and endplay explains what you are looking for.
• Refill with the ATF Suzuki specifies for the vehicle. On a Japanese import, the original handbook lists the fluid.

Will this fit my Suzuki Jimny?

The listing covers the 0.7L and 1.3L Jimny from 2005 to 2015 with the TW-40L or TW-40LS automatic. The third-generation Jimny was sold with a five-speed manual or a four-speed automatic, so confirm it is the automatic and read the stamp on the case.

What is in the box?

One overhaul kit with gaskets and seals, one complete friction plate set and one complete steel plate set. Hard parts such as drums, gears, bushings and the filter are not listed as included.

My 2002 Every van has an automatic. Is it a TW-40?

Not necessarily. Published specs for the 1999-2005 Every list a three-speed automatic. Count the gears on a road test and check the case stamp before ordering.

Can I rebuild it without special tools?

You need a clutch spring compressor, snap ring pliers, a way to air-check circuits and a dial indicator for endplay. The unit is small and simple, which makes it a reasonable home-shop rebuild.

Which fluid should I use after the rebuild?

Use the ATF listed in the vehicle's handbook. Suzuki, Mitsubishi, Nissan and the Taiwan-market vans may not all call for the same fluid.

• Transmission Slipping Diagnosis Guide
• Rebuild vs Replace vs Reman Transmission
• Transmission Thrust Washers and End Play
• Shift Flare vs Slip: What Is the Difference