Direct Clutch Components: Disassembly

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Install direct clutch assembly (1) to center support (2) and with 4 - 8 kg/cm² air pressure applied to second fluid hole from the left, measure stroke of direct clutch piston as shown in the figure.
If it is not within standard range, use 3.55 mm, 3.75 mm or 4.0 mm (0.140 in., 0.147 in. or 0.157 in.) clutch backing plate to adjust it to standard stroke.

Direct clutch piston standard stroke
1. 0.90 - 1.30 mm (0.035 - 0.051 in.)
Fig 1: Installing Direct Clutch Assembly To Center Support
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch assembly from center support and then remove retaining ring.

Fig 2: Removing Direct Clutch Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove clutch backing plate (1) and then remove clutch disc (3) and clutch plate (2).

Fig 3: Removing Clutch Backing Plate
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and hydraulic press (1), compress direct clutch piston return spring (3) and remove retaining return spring ring (2).
Special tool
1. (A): 09926-98310
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

Fig 4: Removing Retaining Return Spring Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch piston return spring.
Install direct clutch cylinder to center support.
Remove direct clutch piston by blowing air into the second hole from the left as shown in the figure. Also, remove direct clutch inner piston by blowing air into hole at the extreme right. And then remove O-rings from pistons.

Fig 5: Installing Direct Clutch Cylinder To Center Support

Courtesy of SUZUKI OF AMERICA CORP.