Underdrive Clutch and One-Way No. 3 Clutch Disassembly and Reassembly: Reassembly

Reference: UNDERDRIVE CLUTCH AND ONE-WAY NO. 3 CLUTCH INSPECTION 

1. After applying A/T fluid to new O-rings and install O-rings (1) to underdrive clutch piston (2).
2. Install underdrive clutch piston (2) to underdrive clutch drum (3) by pushing with fingers.
   NOTE: Do not twist or deviate O-rings during installation.
   Fig 1: Identifying Underdrive Clutch Piston & Drum

   Courtesy of SUZUKI OF AMERICA CORP.
3. Using special tool and hydraulic press (2), compress underdrive clutch 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 

   (A): 09926-98350 

   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 underdrive clutch piston return spring at its retainer section.
   CAUTION: Be careful when applying pressure, for overpressure will cause plate section of underdrive clutch piston return spring to deform.
   Fig 2: Identifying Special Tool On Underdrive Clutch Piston Return Spring

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install cushion plate "C", separate plates "S", friction plates "F" and retaining plate "R" of coast clutch in the following order.

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

   NOTE: Make sure that "A" section of cushion plate faces toward piston side.
5. Install snap ring (1).
   NOTE: Make sure that opening end of ring is not aligned with groove section of drum.
   Fig 3: Identifying Snap Ring

   Courtesy of SUZUKI OF AMERICA CORP.
6. Measure underdrive clutch piston stroke again, using special tools.

   If measured piston stroke exceeds specified value, replace underdrive clutch retaining plate with new one so that piston stroke is within standard value.

   Special Tool 

   1. 09900-20607 
   2. 09900-20701 

   Overdrive clutch piston stroke 

   Standard: 1.22 - 1.69 mm (0.048 - 0.067 in.) 

   Available underdrive clutch retaining plate thickness 

   3.6 mm (0.141 in.), 3.8 mm (0.150 in.), 4.0 mm (0.158 in.) 

   Fig 4: Measuring Underdrive Clutch Piston Stroke Again

   Courtesy of SUZUKI OF AMERICA CORP.