Direct Clutch: Disassembly

NOTE: Note component direction prior to removal.

Prior to disassembly, place direct clutch drum onto center support. Using a dial indicator and compressed air, measure direct clutch piston stroke while applying 57-114 psi (4-8 kg/cm² ) to OD case oil hole. See Fig 1 . See DIRECT CLUTCH PISTON STROKE SPECIFICATIONS table. If piston stroke is not as specified, inspect discs. Remove direct clutch from center support.

DIRECT CLUTCH PISTON STROKE SPECIFICATIONS

Application	Clearance - In. (mm)
Grand Vitara	.036-.078 (.91-1.99)
Sportage	.040-.089 (1.01-2.25)
Tracker	.008-.069 (.20-1.75)
Vitara	.042-.084 (1.06-2.14)

Remove snap ring, flange, discs and plates. See Fig 2 . Note location and number of components. Using spring compressor, compress piston return spring and remove snap ring. Remove piston return springs.
Place direct clutch drum on center support. Hold direct clutch piston with hand, and apply compressed air to center support to remove direct clutch piston. Apply compressed air to specified hole in center support to remove inner and outer direct clutch piston. See Fig 1 . Remove "O" rings from piston(s).

Fig 1: Measuring Direct Clutch Piston Stroke & Removing Piston Subassembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig 2: Exploded View Of Direct Clutch Components

Courtesy of SUZUKI OF AMERICA CORP.