Overdrive (Planetary Gear Side) 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.

With overdrive (O/D) clutch cylinder (1) held stationary, turn O/D input shaft (2) clockwise to check that it turns smoothly and then counterclockwise to check that it locks.

Fig 1: Turning O/D Input Shaft Clockwise
Courtesy of SUZUKI OF AMERICA CORP.
Remove O/D planetary gear assembly (1).

Fig 2: Removing O/D Planetary Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.
With O/D clutch assembly (2) installed to oil pump, apply 4 to 8 kg/cm² air pressure into fluid hole in oil pump (1) and measure stroke of clutch piston. If it is not within standard range, replace cushion clutch plate or clutch disc.
Standard stroke of clutch piston

1.47 - 2.28 mm (0.058 - 0.090 in.)

Fig 3: Identifying O/D Clutch Assembly And Fluid Hole In Oil Pump
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining ring (1) and then remove brake hub (2).

Fig 4: Removing Retaining Ring And Brake Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining clutch ring (1) cushion plate, backing plate and clutch disc in that order.

Fig 5: Removing Retaining Clutch Ring Cushion Plate, Backing Plate And Clutch Disc
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With clutch piston return spring compressed with special tools, remove clutch piston return spring.
Special tool

(A): 09918-48211

(B): 09926-98320

(C): 09918-48220

Fig 6: Removing Clutch Piston Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Install O/D clutch cylinder to oil pump (2). Apply compression air into fluid hole in oil pump (2) and remove clutch piston (1).
Remove piston inner O-ring and piston outer O-ring from clutch piston (1).

Fig 7: Removing Piston Inner O-Ring And Piston Outer O-Ring From Clutch Piston
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining ring from O/D planetary gear and then remove one-way clutch, thrust planetary washer and thrust bearing.

Fig 8: Removing Retaining Ring From O/D Planetary Gear
Courtesy of SUZUKI OF AMERICA CORP.