Oil Pump, 2nd Coast Brake and 2nd Brake Disassembly and Reassembly: Reassembly

Reference: OIL PUMP, 2ND BRAKE AND 2ND COAST BRAKE INSPECTION 

1. Press-fit new oil pump oil seal (1) using special tool and hammer and then apply grease to its lip portion.

   Special Tool 

   1. 09913-85210

      : Grease 99000-25030 

      Fig 1: Installing Oil Pump Oil Seal

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2. After applying A/T fluid to gears, install driven gear (1) and drive gear (2) to oil pump body (3) aligning marks on the gears.
3. Apply A/T fluid to new O-ring (4) and install it to oil pump body.
4. Install oil pump plate (5).
   Fig 2: Installing Driven Gear

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5. Install stator shaft (1) to oil pump body and tighten bolts (2) to specification.

   Tightening torque 

   Oil pump cover bolts a: 6.5 N.m (0.65 kg-m, 4.7 lb-ft) 

   Oil pump cover bolts b: 12 N.m (1.2 kg-m, 8.7 lb-ft) 

   Fig 3: Installing Stator Shaft To Oil Pump Body

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6. After applying A/T fluid to new O-rings and install it to 2nd brake piston.
7. Press 2nd brake piston into starter shaft.
   NOTE: Do not twist or deviate O-rings during installation.
   Fig 4: Installing 2nd Brake Piston Into Starter Shaft

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8. Install 2nd brake piston return spring.
9. Install cushion plate "C", separator plates "S", friction plates "F" and retaining plate "R" with flat end facing to friction plates side in the following order.

   C --> S --> F --> S --> F --> S --> F --> S --> F --> R

10. Install snap ring.
    NOTE: Make sure that opening end of ring is not aligned with groove section of starter shaft.
    Fig 5: Installing Snap Ring

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11. Apply A/T fluid to new O-rings and install them to 2nd coast brake piston.
12. Press 2nd coast brake piston (1) into starter shaft (2).
    NOTE: Do not twist or deviate O-rings during installation.
    Fig 6: Pressing 2nd Coast Brake Piston Into Starter Shaft

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13. Install 2nd coast brake piston return spring (1).
14. Using special tool and hydraulic press (2), compress 2nd coast brake piston return spring (1) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 in.) lower than snap ring groove and install snap ring (3).

    Special Tool 

    1. 09926-98350
       CAUTION: Be careful when applying pressure, for overpressure will cause plate section of spring to deform.
       NOTE:

       • When installing return spring, be careful so that return spring will not fall or tilt.
       • Do not align opening in snap ring with lug of 2nd coast brake piston return spring at its retainer section.
       Fig 7: Compressing 2nd Coast Brake Piston Return Spring

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15. Install separator plates "S", friction plates "F" and retaining plate "R" in the following order.

    S --> F --> S --> F --> R

    NOTE: Make sure that 2nd brake piston return spring is inserted in 2nd coast brake retaining plate boss.
16. Using special tool and hydraulic press (1), compress 2nd brake piston return spring (2) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 in.) lower than snap ring groove and install snap ring.

    Special Tool 

    1. 09941-51010
       CAUTION: Be careful when applying pressure, for overpressure will cause plate section of spring to deform.
    NOTE:

    • When installing return spring, be careful so that return spring will not fall or tilt.
    • Do not align opening in snap ring with lug of 2nd brake piston return spring at its retainer section.
      Fig 8: Installing Snap Ring

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17. Measure 2nd brake piston stroke again, using special tools.

    If measured piston stroke exceeds specified value, check for an improper installation.

    Special Tool 

    1. 09900-20607 
    2. 09900-20701 

       2nd brake piston stroke 

       Standard: 1.91 - 2.69 mm (0.075 - 0.106 in.) 

       Fig 9: Measuring 2nd Brake Piston Stroke

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18. Measure 2nd coast brake piston stroke, using special tools.

    If measured piston stroke exceeds specified value, check for an improper installation.

    Special Tool 

    1. 09900-20607 
    2. 09900-20701 

       2nd coast brake piston stroke 

       Standard: 0.82 - 1.66 mm (0.032 - 0.156 in.) 

       Fig 10: Measuring Coast Brake Piston Stroke

       Courtesy of SUZUKI OF AMERICA CORP.
19. Install 2nd coast brake thrust washer (1).

    If measured piston stroke exceeds specified value, check for an improper installation.

    NOTE: Make sure lugs of 2nd coast brake thrust washer align with 2nd coast brake piston return spring.

Fig 11: Installing Coast Brake Thrust Washer

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