Forward and Direct Clutch Disassembly and Reassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

Remove snap ring (1) using flat end rod or the like.
Remove retaining plate "R", friction plates "F" and separator plates "S" in the following order.
R --> F --> S --> F --> S --> F --> S --> F --> S

NOTE: Measure thickness of removed retaining plate and record for reference of piston stroke confirmation.

Fig 1: Identifying Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring (1) using flat end rod or the like.
Remove retaining plate, friction plates and separator plates.
NOTE: Measure thickness of removed retaining plate and record for reference of piston stroke confirmation.

Fig 2: Identifying Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and hydraulic press, compress direct clutch piston return spring and remove snap ring (1).
Special Tool
1. 09926-95420
2. 09940-51710
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of direct clutch piston return spring to deform.
Remove direct clutch piston return spring (2).

Fig 3: Identifying Special Tool On Direct Clutch Piston Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
For removing forward clutch piston and direct clutch piston, install forward and direct clutch assembly (1) to transaxle rear cover (2).
Remove direct clutch piston (3) with O-rings by applying compressed air (400 - 800 kPa, 4 - 8 kg/cm² , 57 - 113 psi) through oil hole (4).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.

Fig 4: Applying Compressed Air Into Oil Hole (1 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.
Remove forward clutch piston (1) with O-rings by applying compressed air (400 - 800 kPa, 4 - 8 kg/cm² , 57 - 133 psi) from through oil hole (2).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.

Fig 5: Applying Compressed Air Into Oil Hole (2 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal ring (1) from input shaft (2).
NOTE: Never reuse removed oil seal ring.

Fig 6: Identifying Oil Seal Ring From Input Shaft
Courtesy of SUZUKI OF AMERICA CORP.