Forward Clutch Disassembly and Assembly: Assembly

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.

Apply A/T fluid to forward input shaft O-rings, install forward clutch piston and piston return spring (2) to forward input shaft and then install return spring ring with special tool and hydraulic press.

CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring (2) to deform.

NOTE:

When installing return spring (2), be careful so that return spring (2) will not fall or tilt.
Do not align opening in retaining ring (1) with lug of forward clutch piston return spring (2) at its retainer section.

Special tool

(A): 09926-98310

Fig 1: Identifying Return Spring And Retaining Ring

Courtesy of SUZUKI OF AMERICA CORP.

2) Install clutch discs from the thinnest one to thicker ones to piston side and then install retaining clutch ring.
NOTE:
- Refer to "FORWARD CLUTCH COMPONENTS: " when installing each component.
- Do not match opening in retaining clutch ring and dent in forward clutch input shaft.
3) Install bearing races and thrust bearing.

Fig 2: Installing Bearing Races And Thrust Bearing
Courtesy of SUZUKI OF AMERICA CORP.
4) Install forward clutch hub (3), direct clutch hub (2) and retaining ring (1) to input shaft (4) in that order.

Fig 3: Installing Forward Clutch Hub, Direct Clutch Hub And Retaining Ring To Input Shaft
Courtesy of SUZUKI OF AMERICA CORP.