Direct Clutch Disassembly and Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Install direct clutch assembly (1) to center support (2) and with 4 - 8 kg/cm² air pressure applied to second fluid hole from the left, measure stroke of direct clutch piston as shown in the figure.
If it is not within standard range, use 3.55 mm, 3.75 mm or 4.0 mm (0.140 in., 0.148 in. or 0.157 in.) clutch backing plate to adjust it to standard stroke.

Standard direct clutch piston stroke

For J20 engine model: 1.06 - 2.14 mm (0.042 - 0.084 in.)

For H25 engine model: 0.91 - 1.99 mm (0.036 - 0.078 in.)

Fig 1: Measuring Stroke Of Direct Clutch Piston
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch assembly from center support and then remove retaining ring.

Fig 2: Removing Direct Clutch Assembly From Center Support
Courtesy of SUZUKI OF AMERICA CORP.
Remove clutch backing plate (1) and then remove clutch disc (3) and clutch plate (2).

Fig 3: Removing Clutch Backing Plate, Clutch Disc And Clutch Plate
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and hydraulic press (1), compress direct clutch piston return spring (3) and remove retaining return spring ring (2).
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

Special tool

(A): 09926-98310

Fig 4: Identifying Hydraulic Press, Direct Clutch Piston Return Spring And Retaining Return Spring Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch piston return spring.
Install direct clutch cylinder to center support.
Remove direct clutch piston by blowing air into the second hole from the left as shown in the figure. Also, remove direct clutch inner piston by blowing air into hole at the extreme right. And then remove O-rings from pistons.

Fig 5: Removing Direct Clutch Piston Return Spring

Courtesy of SUZUKI OF AMERICA CORP.