Overdrive (Planetary Gear Side) Disassembly and Assembly: Disassembly

With overdrive (O/D) clutch cylinder (1) held stationary, turn O/D input shaft (2) clockwise to check that it turns smoothly and then counterclockwise to check that it locks.

Fig 1: Checking O/D Input Shaft Operation
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Remove O/D planetary gear assembly (1).

Fig 2: Identifying O/D Planetary Gear Assembly And O/D Clutch Cylinder
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With O/D clutch assembly (2) installed to oil pump, apply compressed air (400 - 800 kPa, 4 - 8 kgf/cm² , 57 - 113 psi) to oil hole (3) in oil pump (1) and measure stroke of clutch piston. If it is not within standard range, replace cushion clutch plate or clutch disc.
Standard stroke of clutch piston

1.74 - 2.44 mm (0.069 - 0.096 in.)

Fig 3: Measuring Stroke Of Clutch Piston
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Remove retaining ring (1) and then remove brake hub (2).

Fig 4: Identifying Retaining Ring And Brake Hub
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Remove retaining ring (1), cushion plate (2), clutch plate (3) and clutch disc (4) in that order.

Fig 5: Identifying Retaining Ring, Cushion Plate, Clutch Plate And Clutch Disc
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With clutch piston return spring compressed with special tools, remove clutch piston return spring.
Special Tool

(A): 09918-48211

(B): 09926-98320

(C): 09918-48220

Fig 6: Removing Clutch Piston Return Spring
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Install O/D clutch cylinder to oil pump (2). Apply compression air into fluid hole (3) in oil pump (2) and remove clutch piston (1).
Remove piston inner O-ring and piston outer O-ring from clutch piston (1).

Fig 7: Removing Clutch Piston
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Remove retaining ring from O/D planetary gear and then remove one-way clutch, thrust washer and thrust bearing.

Fig 8: Removing Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.