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4-5 Clutch Drum Assembly Assemble

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: 4-5 CLUTCH DRUM 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: Identifying Piston Inner Seals, 4-5 Clutch Piston & 4-5 Clutch Drum Assembly
G04846102Courtesy of SUZUKI OF AMERICA CORP.
NOTE: Soak the new clutch discs in automatic transmission fluid for at least 2 hours before installation.
  1. Apply automatic transmission fluid to the new piston seals.
  2. Install a new piston inner seal (581) and a new piston outer seal (583) on to the 4-5 clutch piston (582).
  3. Apply automatic transmission fluid to the inner and outer seal surfaces of the 4-5 clutch drum assembly (584).
  4. Install the 4-5 clutch piston assembly (582) into the 4-5 clutch drum assembly (584).
    Fig 2: Identifying 4-5 Clutch Piston Return Spring Assembly
    G04846103Courtesy of SUZUKI OF AMERICA CORP.
  5. Install the 4-5 clutch piston return spring assembly (580) on to the 4-5 clutch piston assembly, indexing the springs to the holes in the 4-5 clutch piston assembly.
    Fig 3: Installing 4-5 Clutch Piston Return Spring Retaining Ring
    G04846104Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Make sure that the end gap of the retaining ring is not aligned with the spring retainer claw.
  6. Install the 4-5 clutch piston return spring retaining ring (579).
    1. Place the J 25024-A (3) in a vise with the forcing screw on the bottom and backed out.
    2. Place the J 45186 (1) on the 4-5 clutch piston return spring assembly (580).
    3. Place the J 21420-2 (4) from the J 23327 on top of the forcing screw of J 25024-A (3).
    4. Place the clutch housing with the J 45186 (1) on the J 21420-2 (4) and under the arms of J 25024-A (3).
    5. With the forcing screw, compress the clutch spring to allow the installation of the retaining ring.
    6. Use J 28585 (2) or snap ring pliers to install the retaining ring (579).
      Fig 4: Identifying Fiber Plates, Steel Plates & 4-5 Clutch Drum Assembly
      G04846105Courtesy of SUZUKI OF AMERICA CORP.
      NOTE: Make sure that you have the correct number of plates, and that they are in the correct order.
  7. Install the 4 fiber plates (577) and the 4 steel plates (578) into the 4-5 clutch drum assembly (584).
  8. Install the 4-5 clutch backing plate (576) into the 4-5 clutch drum assembly (584).
    Fig 5: Identifying 4-5 Clutch Backing Plate Retaining Ring & 4-5 Clutch Drum Assembly
    G04846106Courtesy of SUZUKI OF AMERICA CORP.
  9. Using J 28585 install the 4-5 clutch backing plate retaining ring (575) into the groove of the 4-5 clutch drum assembly (584). Make sure that the end gap of the retaining ring is not aligned with one of the cutouts in the drum.

Reference: 4-5 CLUTCH PISTON TRAVEL MEASUREMENT .

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