4-5 Clutch Drum Assembly Disassemble: Notes

Reference: 4-5 CLUTCH ASSEMBLY REMOVAL .

Special Tool 

J 23327 Clutch Spring Compressor 

J 25024-A Servo Piston/Clutch Spring Compressor 

J 28585 Snap Ring Remover 

J 45186 Forward and Direct Clutch Spring Compressor 

Fig 1: Removing 4-5 Clutch Backing Plate Retaining Ring & 4-5 Clutch Drum Assembly

Courtesy of SUZUKI OF AMERICA CORP.

1. Using J 28585 remove the 4-5 clutch backing plate retaining ring (575) from the 4-5 clutch drum assembly (584).
2. Remove the following components from the 4-5 clutch drum assembly (584):
   • The 4-5 clutch backing plate (576)
   • The 4 fiber plates (577)
   • The 4 steel plates (578)
     Fig 2: Identifying 4-5 Clutch Piston Return Spring Assembly

     Courtesy of SUZUKI OF AMERICA CORP.
3. Remove the 4-5 clutch piston return spring assembly (580).
   1. Place the J 25024-A (3) in a vise with the forcing screw on the bottom and backed out.
   2. Place the J 45186 (1) on the 4-5 clutch piston return spring assembly (580).
   3. Place the J 21420-2 (4) from the J 23327 on top of the forcing screw of J 25024-A (3).
   4. Place the clutch housing with the J 45186 (1) on the J 21420-2 (4) and under the arms of J 25024-A (3).
   5. With the forcing screw, compress the clutch spring to allow the removal of the retaining ring.
   6. Use J 28585 (2) or snap ring pliers to remove the retaining ring (579).
4. Remove the 4-5 clutch piston return spring assembly (580).
   Fig 3: Identifying Front Differential Transfer Drive Gear Assembly & 4-5 Clutch Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
   WARNING: Wear safety glasses when using compressed air in order to prevent eye injury.
5. Using the case as a holding fixture, install the front differential transfer drive gear assembly (14) into the output gear bore.
6. Install the 4-5 clutch assembly (15) onto the front differential transfer drive gear assembly (14), with the clutch piston facing up, so that the fluid passages are around the sealing rings.
   Fig 4: Identifying 4-5 Clutch Piston Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
7. Apply air pressure to the fluid passage (1) in the end of the front differential transfer drive gear assembly shaft and remove the 4-5 clutch piston assembly (582).
8. Remove the 4-5 clutch drum assembly and the front differential transfer drive gear assembly from the case.
   Fig 5: Identifying Piston Inner Seal, Piston Outer Seal & 4-5 Clutch Piston

   Courtesy of SUZUKI OF AMERICA CORP.
9. Remove the piston inner seal (581) and the piston outer seal (583) from the 4-5 clutch piston (582).