Underdrive Clutch and One-Way No. 3 Clutch Inspection

Reference: UNDERDRIVE CLUTCH AND ONE-WAY NO. 3 CLUTCH DISASSEMBLY AND REASSEMBLY 

1. Check that sliding surfaces of friction, separator and retaining cushion plates are not worn or burnt. If necessary, replace.
   NOTE:

   • If friction plate lining is exfoliated, discolored or worn hardly, replace all friction plates.
   • Before assembling new friction plates, soak them in A/T fluid for at least two hours.
   Fig 1: Identifying Friction Plates

   Courtesy of SUZUKI OF AMERICA CORP.
2. Measure height of several underdrive clutch piston return spring including plate. If necessary, replace with a new one.

   Underdrive clutch piston return spring height 

   Standard: 20.1 mm (0.79 in.) 

   NOTE: Do not apply excessive force when measuring spring height or it is not measured accurately.
   Fig 2: Measuring Height Of Several Underdrive Clutch Piston Return Spring

   Courtesy of SUZUKI OF AMERICA CORP.
3. Shake underdrive clutch piston lightly and check that check ball (1) is not stuck. Check that valve does not have leaks by applying low-pressure cam pressed air. If necessary, replace underdrive clutch piston.
   Fig 3: Identifying Check Ball

   Courtesy of SUZUKI OF AMERICA CORP.
4. Measure inside diameter of underdrive clutch drum bushing (1), using special tools. If inside diameter exceeds limit, replace underdrive clutch drum.

   Underdrive clutch drum bushing inside diameter limit 

   28.57 mm (1.124 in.) 

   Special Tool 

   1. 09900-20607 
   2. 09900-22403 
   NOTE: Perform measurement at several point.
   Fig 4: Measuring Inside Diameter Of Underdrive Clutch Drum Bushing

   Courtesy of SUZUKI OF AMERICA CORP.