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Home >> Suzuki >> 2001 >> Vitara JS, 4D Utility, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission Overhaul - Aw 03-72LE & Aw 03-73LE >> Component Disassembly & Reassembly >> Forward Clutch >> Disassembly & Inspection
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Disassembly & Inspection

  1. Remove the following components from the input shaft assembly:
    • The snap ring. See Fig 2 .
    • The direct clutch input hub.
    • The forward clutch hub.
  2. Remove the following components from the input shaft:
    • The thrust bearing No. 2 race. See Fig 3 .
    • The thrust rear bearing race.
    • The forward clutch thrust bearing.
  3. Temporarily install the direct clutch input hub and the snap ring into the forward clutch. See Fig 4 . Temporarily install the forward clutch into the overdrive case. See Fig 5 .
  4. Measure the forward clutch piston stroke using Dial Indicator Set and Magnetic Base:
    1. Place the dial indicator plunger on the forward clutch piston.
    2. Apply 58-114 psi (4.08-8.02 Kg/CM2 ) of compressed air into the fluid passage at the right of the cut in the overdrive case.
    3. Measure forward clutch piston stroke. See FORWARD CLUTCH PISTON SPECIFICATIONS  table.
    4. If the forward clutch piston stroke is not within specifications, install a 0.071 or 0.079" (1.80 mm or 2.00 mm) clutch disc in order to adjust.
  5. Remove the forward clutch from the overdrive case. Remove the direct clutch input hub and snap ring from the forward clutch hub.
  6. Remove the following forward clutch hub components:
    • The snap ring.
    • The clutch plates.
    • The discs.
    WARNING: When applying pressure, use care, as excessive pressure will cause a section of piston return springs to deform.
  7. Compress the forward clutch piston return springs using the Clutch Spring Compressor, and a press while removing the snap ring. See Fig 6 . Remove 18 forward clutch piston return springs. Inspect for damage, cracks, excessive outside wear or deterioration.
  8. Install the forward clutch to the overdrive case. See Fig 7 . Apply low compressed air pressure to the fluid passage at the right of the overdrive case in order to remove the forward clutch piston. Remove the forward clutch piston "O" Rings.
  9. Measure the free length of the forward clutch piston return springs. See FORWARD CLUTCH PISTON SPECIFICATIONS  table. Replace if not within specifications.
  10. Clean all forward clutch components. Allow the components to air dry. Inspect the forward clutch disc for excessive wear or damage. Replace as necessary.
  11. Inspect the forward clutch piston for cracks or porosity. Replace as needed. Shake the piston in order to inspect the forward clutch piston check ball free movement. Apply low compressed air pressure to the check ball opening in order to inspect for leaks. Repair or replace as necessary.
FORWARD CLUTCH PISTON SPECIFICATIONS

Application Stroke Clearance - In. (mm) Return Spring Free Length - In. (mm)
Forward Clutch Piston .056-.088 (1.40-2.24) .595 (15.13)
Fig 1: Exploded View Of Forward Clutch Components
G00047145Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Identifying Input Shaft Assembly Components
G00286825Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing Input Shaft Components
G00286826Courtesy of GENERAL MOTORS CORP.
Fig 4: Temporarily Install Direct Clutch Input Hub & Snap Ring
G00286828Courtesy of GENERAL MOTORS CORP.
Fig 5: Measuring Forward Clutch Piston Stroke
G00286827Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing Forward Clutch Piston Return Spring Snap Ring
G00286829Courtesy of GENERAL MOTORS CORP.
Fig 7: Applying Air Pressure To Remove Forward Clutch
G00286830Courtesy of GENERAL MOTORS CORP.
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