Forward and Direct Clutch Assembly Disassemble

Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY REMOVAL 

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: Identifying Input Shaft O-Ring Seal

Courtesy of SUZUKI OF AMERICA CORP.

1. Remove the input shaft O-ring seal (570) from the forward and direct clutch housing assembly - with input shaft (567).
   Fig 2: Identifying Forward Clutch Housing Thrust Bearing And Forward Clutch Housing Thrust Bearing Race

   Courtesy of SUZUKI OF AMERICA CORP.
2. Remove the forward clutch housing thrust bearing (569) and the forward clutch housing thrust bearing race (568) from the forward and direct clutch housing assembly - with input shaft (567).
   Fig 3: Removing Forward Clutch Backing Plate Retaining Ring

   Courtesy of SUZUKI OF AMERICA CORP.
3. Using J 28585, remove the forward clutch backing plate retaining ring (550) from the forward and direct clutch housing assembly - with input shaft (567).
   Fig 4: Identifying Forward Clutch Backing Plate, Fiber Plates And Steel Plates

   Courtesy of SUZUKI OF AMERICA CORP.
4. Remove the following components from the forward and direct clutch housing assembly - with input shaft (567):
   • The forward clutch backing plate (551)
   • The 4 forward clutch fiber plates (552)
   • The 4 forward clutch steel plates (553)
     Fig 5: Removing Direct Clutch Backing Plate Retaining Ring

     Courtesy of SUZUKI OF AMERICA CORP.
5. Using J 28585, remove the direct clutch backing plate retaining ring (554) from the forward and direct clutch housing assembly - with input shaft (567).
   Fig 6: Identifying Direct Clutch Backing Plate, Fiber Plates, Steel Plates And Apply Plate

   Courtesy of SUZUKI OF AMERICA CORP.
6. Remove the following components from the forward and direct clutch housing assembly - with input shaft (567):
   • The direct clutch backing plate (555)
   • The 4 direct clutch fiber plates (556)
   • The 4 direct clutch steel plates (557)
   • The direct clutch apply plate (558)
     Fig 7: Removing Direct Clutch Spring Retaining Ring

     Courtesy of SUZUKI OF AMERICA CORP.
7. Remove 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 removal of the retaining ring.
   5. Use J 28585 (3) or snap ring pliers to remove the retaining ring.
   6. Remove the tools.
      Fig 8: Identifying Direct Clutch Spring Assembly

      Courtesy of SUZUKI OF AMERICA CORP.
8. Remove the direct clutch spring assembly (560).
   Fig 9: Removing Direct Clutch Piston

   Courtesy of SUZUKI OF AMERICA CORP.
   WARNING: Wear safety glasses when using compressed air in order to prevent eye injury.
9. Install the forward and direct clutch housing assembly with input shaft (567) onto the transmission case cover (19).
10. While pulling on the piston by hand, apply compressed air into the fluid passage (C2) in order to remove the direct clutch piston (562).
    Fig 10: Identifying Direct Clutch Piston Seals And Direct Clutch Piston

    Courtesy of SUZUKI OF AMERICA CORP.
11. Remove the direct clutch piston inner seal (561) and the direct clutch piston outer seal (563) from the direct clutch piston (562).
    Fig 11: Removing Forward Clutch Piston

    Courtesy of SUZUKI OF AMERICA CORP.
    WARNING: Wear safety glasses when using compressed air in order to prevent eye injury.
12. While pulling upward on the piston by hand, apply compressed air into the fluid passage (C1) in order to remove the forward clutch piston (565).
    Fig 12: Identifying Forward Clutch Piston And Forward Clutch Piston Seals

    Courtesy of SUZUKI OF AMERICA CORP.
13. Remove the forward clutch piston inner seal (564) and the forward clutch piston outer seal (566) from the forward clutch piston (565).

    Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY ASSEMBLE