Forward 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.

After removing retaining ring (1), remove direct clutch input hub (2) and forward clutch hub (3).

Fig 1: Removing Retaining Ring, Direct Clutch Input Hub And Forward Clutch Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing race and thrust bearing.

Fig 2: Removing Bearing Race And Thrust Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install direct clutch input hub (1) and retaining ring (2).

Fig 3: Installing Direct Clutch Input Hub And Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install forward clutch (2) to O/D case (1). Apply 4 - 8 kg/cm² air pressure into fluid hole at the right of cut in O/D case and measure movement of forward clutch piston.
If measured value is not within standard range, use either 1.8 mm (0.071 in.) or 2.0 mm (0.079 in.) clutch disc to adjust it to standard value.

Standard forward clutch piston movement

1.40 - 2.24 mm (0.055 - 0.088 in.)

Fig 4: Measuring Standard Forward Clutch Piston Movement
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining ring (1) and then remove direct clutch input hub.
Remove retaining ring and then remove all clutch discs.

Fig 5: Removing Retaining Ring And Direct Clutch Input Hub
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and hydraulic press, compress forward clutch piston return spring and remove retaining return spring.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

Special tool

(A): 09926-98310

Fig 6: Identifying Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove forward clutch piston return spring.
Install forward clutch to O/D case. Blow low pressure air into fluid hole at the right of cut in O/D case to remove forward clutch piston.

Fig 7: Blowing Low Pressure Air Into Fluid Hole At Right Of Cut In O/D Case
Courtesy of SUZUKI OF AMERICA CORP.