Forward 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.

After removing retaining ring (1), remove direct clutch input hub (2) and forward clutch hub (3).

Fig 1: Removing Direct Clutch Input Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing race and thrust bearing.

Fig 2: Removing Bearing Race & Thrust Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install direct clutch input hub (1) and retaining ring (2).

Fig 3: Installing Direct Clutch Input Hub & Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install forward clutch (2) to O/D case (1). Apply 4 - 8 kg/cm² air pressure into fluid hole at the right of cut in O/D case and measure movement of forward clutch piston.
If measured value is not within standard range, use either 1.8 mm (0.071 in.) or 2.0 mm (0.079 in.) clutch disc to adjust it to standard value.

Standard forward clutch piston movement
1. 1.40 - 1.70 mm (0.055 - 0.067 in.)
Fig 4: Installing Forward Clutch
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining ring (1) and then remove direct clutch input hub.
Remove retaining ring and then remove all clutch discs.

Fig 5: Removing Retaining Ring & All Clutch Discs
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and hydraulic press, compress forward clutch piston return spring and remove retaining return spring.
Special tool
1. (A): 09926-98310
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.
Remove forward clutch piston return spring.

Fig 6: Removing Forward Clutch Piston Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Install forward clutch to O/D case. Blow low pressure air into fluid hole at the right of cut in O/D case to remove forward clutch piston.

Fig 7: Installing Forward Clutch To O/D Case

Courtesy of SUZUKI OF AMERICA CORP.