Front Internal Gear and Low and Reverse Clutch Installation

Reference: FRONT INTERNAL GEAR AND OVERRUN CLUTCH ASSEMBLE .

Special Tool 

J 28585 Snap Ring Remover 

Fig 1: Identifying Front Internal Gear Thrust Washer Race, Gear & Gear Thrust Bearing

Courtesy of SUZUKI OF AMERICA CORP.

1. Install the front internal gear thrust washer race (530) on top of the output gear assembly.
2. Install the front internal gear thrust bearing assembly (519) on top of the front internal gear thrust washer race (530).
   NOTE: The front internal gear (526) should turn freely counterclockwise, and should lock clockwise.
3. Install the front internal gear and overrun roller clutch assembly (526).
   Fig 2: Identifying Steel Plates, Low & Reverse Clutch Backing Plate

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE:

   • The apply plate (515) is 2.5 mm (0.100 in) thick.
   • The steel plates (517) are 1.95 mm (0.077 in) thick.
   • The backing plate (520) IS 3.8 mm (0.150 in) thick.
4. Install the low and reverse clutch apply plate (515)
5. Install the 4 steel plates (517) and the 5 fiber plates (516).
6. Install the low and reverse clutch backing plate (520).
   Fig 3: Identifying Low & Reverse Clutch Plate Retaining Ring

   Courtesy of SUZUKI OF AMERICA CORP.
7. Using J 28585 install the low and reverse clutch plate retaining ring (518), aligning the openings of the retaining ring towards the dowel pin in the case. Both ends of the retaining ring lock in the lug.

   Reference: LOW AND REVERSE CLUTCH PISTON TRAVEL MEASUREMENT .