Clutch Drum & Input Shaft Assembly Disassembly

WARNING: This page is about a different car, the 2004 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.

Place oil pump (1) onto torque converter (2), and then place clutch drum and input shaft assembly (3) onto oil pump (1).

Fig 1: Placing Oil Pump Onto Torque Converter
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring (1) from clutch drum and input shaft assembly (2) by using flat end rod or the like.

Fig 2: Removing Snap Ring From Clutch Drum & Input Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse clutch hub (1) with reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 4 reverse clutch discs and 3 reverse clutch plates from clutch drum assembly.

Fig 3: Removing Reverse Clutch Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse clutch reaction sleeve (1) from reverse clutch hub.

Fig 4: Removing Reverse Clutch Reaction Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Remove clutch cushion plate (1), reverse clutch flange "F", reverse clutch plates "P" and reverse clutch discs "D" from reverse clutch hub.

Fig 5: Removing Clutch Cushion Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch hub (1) from clutch drum assembly.

Fig 6: Removing Direct Clutch Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2 thrust needle roller bearings (1) from direct clutch hub.

Fig 7: Removing Thrust Needle Roller Bearings
Courtesy of SUZUKI OF AMERICA CORP.
Remove forward clutch hub (1) from clutch drum assembly.

Fig 8: Removing Forward Clutch Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove thrust bearing race No.2 (1) and thrust bearing race (2) from forward clutch hub.

Fig 9: Removing Thrust Bearing Race
Courtesy of SUZUKI OF AMERICA CORP.
Remove thrust needle roller bearing (1) from clutch drum assembly.

Fig 10: Removing Thrust Needle Roller Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft assembly (1) from clutch drum assembly.

Fig 11: Removing Input Shaft Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove 3 oil seal rings (1) from input shaft assembly.

Fig 12: Removing Oil Seal Rings
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring (1) from input shaft assembly (2) by using flat end rod or the like.

Fig 13: Removing Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove forward clutch flanges "F", forward clutch discs "D" and forward clutch plates "P" from input shaft assembly.

Fig 14: Removing Forward Clutch Flanges
Courtesy of SUZUKI OF AMERICA CORP.
Compress clutch balancer No.1 and forward clutch return spring (1) until the clutch balancer No.1 is lowered to the place 1-2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool and hydraulic press, and then remove snap ring (2).
CAUTION: Be careful when applying pressure, for overpressure will cause forward clutch return spring to deform.

NOTE: Set special tool to the width of "a" 68 mm (2.652 in.) as shown in figure.

Special tool
1. (A): 09926-96520
Fig 15: Compressing Clutch Balancer & Forward Clutch Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove clutch balancer No.1 (1) and forward clutch return spring (2) from input shaft assembly.

Fig 16: Removing Clutch Balancer
Courtesy of SUZUKI OF AMERICA CORP.
Remove forward clutch piston (1) from input shaft assembly (2) by applying compressed air (392 kPa, 4.0kg/cm2, 57psi) into oil hole (3) of input shaft assembly as shown in figure.

Fig 17: Removing Forward Clutch Piston
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse clutch flange (1) from clutch drum assembly (2).

Fig 18: Removing Reverse Clutch Flange
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2 snap rings (1) from clutch drum assembly (2) by using flat end rod or the like.

Fig 19: Removing Snap Rings
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch flange "F", direct clutch plates "P" and direct clutch discs "D" from clutch drum assembly.

Fig 20: Removing Direct Clutch Flange
Courtesy of SUZUKI OF AMERICA CORP.
Compress clutch balancer No.3 and reverse clutch return spring (1) until the clutch balancer No.3 is lowered to the place 1-2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool and hydraulic press, and then remove snap ring (2).
CAUTION: Be careful when applying pressure, for overpressure will cause reverse clutch return spring to deform.

Special tool
1. (A): 09926-96040
Fig 21: Compressing Clutch Balancer & Reverse Clutch Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse clutch return spring (1) and O-ring (2) from reverse clutch piston.

Fig 22: Removing Reverse Clutch Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse clutch piston sub assembly from clutch drum sub assembly (1).

Fig 23: Removing Reverse Clutch Piston
Courtesy of SUZUKI OF AMERICA CORP.
Compress clutch balancer No.2 and direct clutch return spring (1) until the clutch balancer No.2 is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool and hydraulic press, and then remove snap ring (2).
CAUTION: Be careful when applying pressure, for overpressure will cause direct clutch return spring to deform.

Special tool
1. (A): 09926-96040
Fig 24: Compressing Clutch Balancer & Direct Clutch Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Using 2 screw drivers, remove direct clutch piston sub assembly (1) from clutch drum.

Fig 25: Removing Direct Clutch Piston Sub
Courtesy of SUZUKI OF AMERICA CORP.
Remove clutch balancer No.2 (1) and direct clutch return spring (2) from direct clutch piston sub assembly.

Fig 26: Removing Clutch Balancer & Direct Clutch Return Spring

Courtesy of SUZUKI OF AMERICA CORP.