Forward Clutch Piston Travel Check

Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY ASSEMBLE .

Special Tool 

J 45200 Dial Indicator Set 

J 45166 Dial Indicator Extension Rod - 8 inch 

Fig 1: Applying Compressed Air To C1 Fluid Passage In Case

Courtesy of SUZUKI OF AMERICA CORP.

1. Install the forward and direct clutch assembly (23) onto the transmission case cover (19).
2. Remove the inner forward clutch accumulator cover bolt/screw from the forward clutch accumulator assembly. Install J 45166 (2) in place of the removed bolt.
3. Assemble J 45200 (3) and J 45166 (2) onto the transmission case cover (19).
4. Install the dial indicator extension - OTC # 222545 or equivalent (4) on the dial indicator plunger.
5. Place the dial indicator plunger on the piston as shown and set the dial indicator to zero.
6. Cover the forward clutch accumulator housing (1) with a shop rag to prevent fluid from spraying out the top of the accumulator housing when compressed air is applied to the passage (C2).
   WARNING: When you use compressed air in order to clear fluid passages and to dry parts, always aim the air pressure away from face and eyes. Always wear adequate eye protection in order to avoid injury from dirt and debris that may adhere to parts.
7. Apply compressed air to the C1 fluid passage in the case and measure the forward clutch piston stroke.

   Specification 

   Forward clutch piston stroke: 0.71-1.09 mm (0.028-0.042 in) 

8. If the piston stroke is not within specifications, replace the forward clutch backing plate with the correct thickness.

   Refer to TRANSMISSION CLEARANCE SPECIFICATIONS , Available Forward Clutch Backing Plate Thickness.

   Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY INSTALLATION .