Forward and Direct Clutch Disassembly and Reassembly: Reassembly

Reference: FORWARD AND DIRECT CLUTCH INSPECTION 

1. Apply A/T fluid to new oil seal ring and install new oil seal ring (1) to input shaft (2).
   Fig 1: Identifying Oil Seal Ring Into Input Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
2. Apply A/T fluid to new O-rings and install new O-rings to forward clutch piston.
3. Press forward clutch piston to input shaft.
   NOTE: Do not twist or deviate O-rings during installation.
4. Apply A/T fluid to new O-rings and install O-rings to direct clutch piston.
5. Press direct clutch piston to input shaft.
   NOTE: Do not twist or deviate O-rings during installation.
6. Install direct clutch piston return spring (2).
7. Using special tool and hydraulic press, compress direct clutch piston return spring (2) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 in.) lower than snap ring groove and install snap ring (1).

   Special Tool 

   1. 09926-95420 
   2. 09940-51710 
   NOTE:

   • When installing return spring, be careful so that return spring will not fall or tilt.
   • Do not align opening in snap ring with lug of direct clutch piston return spring at its retainer section.
   CAUTION: Be careful when applying pressure, for overpressure will cause plate section of direct clutch piston return spring to deform.
   Fig 2: Identifying Special Tool On Direct Clutch Piston Return Spring

   Courtesy of SUZUKI OF AMERICA CORP.
8. Install separator plates "S", friction plates "F" and retaining plate "R" in the following order.

   S --> F --> S --> F --> S --> F --> S --> F --> R

9. Install snap ring (1).
   NOTE: Make sure that opening end of ring is not aligned with groove section of input shaft.
   Fig 3: Aligning Groove Section Of Input Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
10. Install separator plates "S", friction plates "F" and retaining plate "R" in the following order.

    S --> F --> S --> F --> S --> F --> S --> F --> R

    NOTE: Make sure that flat end of retaining plate face toward piston side.
11. Install snap ring (1).
    NOTE: Make sure that opening end of ring is not aligned with groove section of input shaft.
    Fig 4: Identifying Snap Ring

    Courtesy of SUZUKI OF AMERICA CORP.
12. Measure forward clutch piston stroke again, using special tools.

    If measured piston stroke exceeds specified value, replace forward clutch retaining plate with new one so that piston stroke is within standard value.

    Special Tool 

    1. 09900-20607 
    2. 09900-20701 

    Forward clutch piston stroke 

    Standard: 1.52 - 1.89 mm (0.059 - 0.074 in.) 

    Available forward clutch retaining plate thickness 

    3.6 mm (0.141 in.), 3.8 mm (0.150 in.), 4.0 mm (0.158 in.) 

    Fig 5: Measuring Forward Clutch Piston Stroke Again

    Courtesy of SUZUKI OF AMERICA CORP.
13. Measure direct clutch piston stroke again, using special tools.

    If measured piston stroke exceeds specified value, replace direct clutch retaining plate with new one so that piston stroke is within standard value.

    Special Tool 

    1. 09900-20607 
    2. 09900-20701 

    Direct clutch piston stroke 

    Standard: 1.52 - 1.89 mm (0.059 - 0.074 in.) 

    Available direct clutch retaining plate thickness 

    3.6 mm (0.141 in.), 3.8 mm (0.150 in.), 4.0 mm (0.158 in.) 

    Fig 6: Measuring Direct Clutch Piston Stroke Again

    Courtesy of SUZUKI OF AMERICA CORP.