Clutch Assembly: Samurai
- Remove shift lever boot. Remove shift lever case cover bolts and remove shift lever. Disconnect negative battery cable. Disconnect back-up light and 5th gear switch. Disconnect starter motor wiring and remove starter. Remove clamps attaching fuel hoses to transmission case. Drain transmission oil.
- Disconnect clutch cable from clutch release lever. Remove both drive shafts. Remove clutch inspection plate. Remove bolts and nuts fastening engine-to-transmission. Remove crossmember and center exhaust pipe. Remove transmission rear mounting bracket.
- Lower transmission from vehicle. Install flywheel holder. Mark pressure plate-to-flywheel for reassembly reference. Remove 6 bolts securing pressure plate to flywheel. Remove pressure plate and clutch disc. Remove clutch release bearing. See Fig 1
.
- Check flywheel and pressure plate contact surface for damage. Replace clutch disc if rivet head depression is .02" (.5 mm) or less. Mount clutch disc on transmission input shaft. Turn disc back and forth to check backlash.
- Replace disc assembly if backlash exceeds .03" (.8 mm). Inspect pressure plate assembly for loose diaphragm-spring rivets. Check diaphragm fingers for wear. Replace parts as necessary.
- Install clutch alignment tool. Position clutch disc to pressure plate and align index marks. Tighten pressure plate-to-flywheel bolts in a diagonal pattern. Complete installation by reversing removal procedure.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.