Forward and Direct Clutch End Play Measurement

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.

Reference: TRANSMISSION CASE COVER AND 1-2 REVERSE CLUTCH ASSEMBLY INSTALLATION .

Special Tool

J 45200 Dial Indicator Set

Fig 1: Identifying Transmission Case Cover Assembly & Transmission Case Assembly

Courtesy of SUZUKI OF AMERICA CORP.

Install the transmission case cover assembly (19) to the transmission case assembly (17).

Fig 2: Measuring Forward & Direct Clutch End Play
Courtesy of SUZUKI OF AMERICA CORP.
Rotate the transmission case so that the front section of the case is facing up.
Install J 45200 as shown and set the dial indicator to zero.
NOTE: Excessive upward pressure will cause an incorrect reading.
With one hand, carefully pull straight up on the forward and direct clutch assembly (23) input shaft until the assembly first bottoms out.
Record the measurement.

Fig 3: Identifying Forward Clutch Housing Selective Thrust Bearing Race
Courtesy of SUZUKI OF AMERICA CORP.
Compare the measurement with the listed specification.
Specification

Forward and direct clutch assembly end play: 0.188 - 0.570 mm (0.007 - 0.022 in)
If out of specification, remove the transmission case cover assembly.
Replace the forward clutch housing selective thrust bearing race (628) as needed to obtain the correct end play specification.

Fig 4: Identifying Transmission Case Cover & Transmission Case Assembly
Courtesy of SUZUKI OF AMERICA CORP.
If the end play measurement is within specifications, rotate the transmission case assembly so that the transmission case cover side is facing up.
Remove the transmission case cover assembly (19) and clean the sealing surfaces of the transmission case cover (19) and the transmission case assembly (17).
Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY INSTALLATION .