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

WARNING: This page is about a different variant/trim than selected.

Remove 2nd coast brake thrust washer (1).

Fig 1: Identifying 2nd Coast Brake Thrust Washer
Courtesy of SUZUKI OF AMERICA CORP.
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 remove snap ring (3).
Special Tool

(A): 09941-51010

CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 2nd brake piston return spring to deform.
Remove retaining plate, friction plates and separator plates.

Fig 2: Identifying Special Tool On 2nd Coast Brake Piston Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and hydraulic press (1), compress 2nd coast 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 remove snap ring (3).
Special Tool

(A): 09926-98350

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

Fig 3: Identifying Special Tool On 2nd Coast Brake Piston Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2nd coast brake piston (1) with O-rings by applying compressed air (400 - 800 kPa, 4 - 8 kg/cm² , 57 - 113 psi) from through oil hole (2).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.

Fig 4: Identifying 2nd Coast Brake Piston
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring (1), using flat end rod or the like.
Remove retaining plate, friction plates, separator plates and cushion plate.
Remove 2nd brake piston return spring (2).

Fig 5: Identifying Snap Ring With 2nd Brake Piston Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2nd brake piston (1) with O-rings applying compressed air (400 - 800 kPa, 4 - 8 kg/cm² , 57 - 113 psi) from through oil hole (2).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.

Fig 6: Identifying 2nd Brake Piston
Courtesy of SUZUKI OF AMERICA CORP.
Remove stator shaft (1) by removing 14 bolts (2).

Fig 7: Identifying Stator Shaft & Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pump plate (1), driven gear (2) and drive gear (3).
Remove O-ring.

Fig 8: Identifying Oil Pump Plate, Driven Gear & Drive Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pump oil seal (1), using special tool.
Special Tool

(A): 09913-50121

NOTE: Never reuse removed oil seal.

Fig 9: Identifying Special Tool On Oil Pump Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.