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Home >> Suzuki >> 2001 >> Vitara JS, 2D Utility, 1.6, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission Overhaul - Aw 03-72LE & Aw 03-73LE >> Component Disassembly & Reassembly >> Direct Clutch >> Reassembly
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Direct Clutch: Reassembly

NOTE: Clutch discs should be soaked in ATF for 15 minutes prior to installation. Lubricate all parts with ATF. Coat thrust bearings and races with Transjel(R) Transmission Assembly Lubricant or petroleum jelly.
NOTE: For special tool part numbers, refer to special tools list. See SPECIAL TOOLS  .
  1. Install NEW "O" Rings to the direct clutch inner and outer pistons. Install the direct clutch inner piston. Install the direct clutch outer piston.
    NOTE: When installing the return springs, DO NOT allow the springs to tilt or fall out of place.
  2. Install the direct clutch piston return springs and seat into the direct clutch piston.
    NOTE: DO NOT align the snap ring opening with the cutout in the direct clutch drum during the next step. See Fig 1 .
  3. Install the direct clutch piston return spring snap ring onto the spring retainer using Clutch Spring Compressor, and a press. Install the direct clutch plates and discs in the following order:
    1. The plate.
    2. The disc.
    3. The plate.
    4. The disc.
    5. The plate.
    6. The disc.
    7. The flange.
  4. Install the direct clutch flange with the flat side facing down and the stepped portion facing upwards. Install the direct clutch snap ring into the direct clutch drum.
  5. Install the following components in the order listed:
    • The race.
    • The thrust bearing and race.
  6. Perform measurement of direct clutch piston stroke. See MEASUREMENT PROCEDURE  .
Fig 1: Identifying Direct Clutch Drum Cutout-To-Snap Ring Orientation
G00286824Courtesy of GENERAL MOTORS CORP.
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