Forward and Direct Clutch Assembly Assemble

Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY DISASSEMBLE .

Special Tool 

J 23327 Clutch Spring Compressor 

J 25024-A Servo Piston/Clutch Spring Compressor 

J 28585 Snap Ring Remover 

J 45186 Forward and Direct Clutch Spring Compressor 

Fig 1: Applying Compressed Air To Ball Check Valve

Courtesy of SUZUKI OF AMERICA CORP.

1. Inspect the clutch plates for being worn or burnt. Replace the plates if worn or burnt.
2. Shake the piston to be sure the ball check valve is free.
   WARNING: Wear safety glasses when using compressed air in order to prevent eye injury.
3. Apply compressed air to the ball check valve to be sure it is not leaking.
4. Inspect the O-ring grooves in the pistons for nicks or scratches.
5. Inspect the clutch plate lugs in the forward clutch piston for grooves.
6. Replace the piston if faulty.
   Fig 2: Identifying Forward & Direct Clutch Housing Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
7. Clean the forward and direct clutch housing assembly and air dry. Ensure to remove all solvent from the oil passages.
8. Inspect the forward and direct clutch housing assembly for the following conditions:
   • Input shaft bearing and bushing areas for excessive wear or damage
   • Rear support bearing surface for excessive wear or damage
   • Piston bores for nicks, grooves or excessive wear
   • Clutch plate lugs for grooves that will prevent the clutch plates from sliding
9. Replace the forward and direct clutch housing if any of the above conditions are found.
   Fig 3: Identifying Forward Clutch Piston Inner Seal & Outer Seal

   Courtesy of SUZUKI OF AMERICA CORP.
10. Apply automatic transmission fluid to the new forward clutch piston seals.
11. Install the forward clutch piston inner seal (564) and the forward clutch piston outer seal (566) onto the forward clutch piston (565).
12. Apply automatic transmission fluid to the inner surface of the forward clutch drum.
13. Apply automatic transmission fluid to the inner surface of the forward clutch drum.
    NOTE: Do not damage the forward clutch piston seals.
14. Press, by hand, the forward clutch piston (565) into the forward and direct clutch housing assembly - with input shaft.
    Fig 4: Identifying Direct Clutch Piston Inner Seal & Outer Seal

    Courtesy of SUZUKI OF AMERICA CORP.
15. Apply automatic transmission fluid to the new direct clutch piston seals.
16. Install the direct clutch piston inner seal (561) and the direct clutch piston outer seal (563) onto the direct clutch piston (562).
17. Apply automatic transmission fluid to the inner surface of the forward clutch piston.
    NOTE: Do not damage the direct clutch piston seals.
18. Press, by hand, the direct clutch piston (562) into the forward clutch piston.
    Fig 5: Identifying Direct Clutch Spring Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
19. Install the direct clutch spring assembly (560) onto the direct clutch piston, indexing the springs into the holes in the direct clutch piston (562).
    Fig 6: Installing Direct Clutch Spring Retaining Ring

    Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Do not align the end gap of the direct clutch spring retaining ring (559) with the spring retainer claw.
20. Install the direct clutch spring retaining ring (559).
    1. Place the J 25024-A (1) in a vise with the forcing screw on the bottom and backed out.
    2. Place the J 45186 (2) over the shaft of the forward direct clutch housing and input shaft assembly (567).
    3. Place the J 21420-2 (4) from the J 23327 on top of the forcing screw of J 25024-A (1).
    4. With the forcing screw, compress the clutch spring to allow the installation of the retaining ring.
    5. Use J 28585 (3) or snap ring pliers to install the retaining ring.
    6. Remove the tools.
       Fig 7: Identifying Direct Clutch Apply Plate, Steel Plates & Fiber Plates

       Courtesy of SUZUKI OF AMERICA CORP.
       NOTE: Make sure the direct clutch apply plate is facing the correct direction.
21. Install the direct clutch apply plate (558). The plate is convex shaped.
22. Install the 4 direct clutch steel plates (557) and the 4 direct clutch fiber plates (556).
23. Install the direct clutch backing plate (555).
    Fig 8: Installing Direct Clutch Backing Plate Retaining Ring

    Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Make sure that the end gap of the direct clutch backing plate retaining ring (554) is not aligned with any of the cut-outs.
24. Install the direct clutch backing plate retaining ring (554) into the groove in the forward and direct clutch housing assembly - with input shaft (567) using J 28585.
    Fig 9: Identifying Forward Clutch Steel Plates, Backing Plate & Fiber Plates

    Courtesy of SUZUKI OF AMERICA CORP.
25. Install the 4 forward clutch steel plates (553) and the 4 forward clutch fiber plates (552).
26. Install the forward clutch backing plate (551).
    Fig 10: Installing Forward Clutch Backing Plate Retaining Ring

    Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Make sure that the end gap of the forward clutch backing plate retaining ring (550) is not aligned with any of the cut-outs.
27. Install the forward clutch backing plate retaining ring (550) into the groove in the forward and direct clutch housing assembly - with input shaft (567) using J 28585.
    Fig 11: Identifying Forward Clutch Housing Thrust Bearing Race & Thrust Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
28. Install the forward clutch housing thrust bearing race (568) 0.81 mm (0.032 in) thickness and the forward clutch housing thrust bearing (569).
    Fig 12: Identifying Input Shaft O-Ring Seal

    Courtesy of SUZUKI OF AMERICA CORP.
29. Apply automatic transmission fluid to the new input shaft O-ring seal (570).
30. Install the new input shaft O-ring seal (570) into the groove of the forward and direct clutch housing assembly - with input shaft (567).

    Reference: DIRECT CLUTCH PISTON TRAVEL CHECK .

    Reference: FORWARD CLUTCH PISTON TRAVEL CHECK .