Rear Internal Gear and Front Carrier Removal

Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY REMOVAL .

Special Tool 

J 45185 Bore Gauge Set 

Fig 1: Identifying Input Shaft Thrust Bearing & Front Sun Gear Assembly

Courtesy of SUZUKI OF AMERICA CORP.

1. Remove the input shaft thrust bearing (540).
2. Remove the front sun gear assembly (544).
3. Remove the rear sun gear thrust bearing (538).
   Fig 2: Identifying Rear Sun Gear Thrust Bearing Race & Rear Internal Gear

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4. Remove the rear sun gear thrust bearing race (537).
5. Remove the rear internal gear (536).
6. Remove the rear internal gear thrust bearing (535).
   Fig 3: Identifying Front Carrier Thrust Bearing Race & Front Carrier Assembly

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7. Remove the front carrier thrust bearing race (543).
8. Remove the front carrier assembly (542).
   Fig 4: Identifying Rear Internal Gear Flange Retaining Ring & Rear Internal Gear

   Courtesy of SUZUKI OF AMERICA CORP.
9. Remove the rear internal gear flange retaining ring (548) from the rear internal gear (536).
10. Remove the rear internal gear flange (547) from the rear internal gear.
11. Remove the other rear internal gear flange retaining ring (548).
    Fig 5: Locating Rear Internal Gear

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12. Clean the rear internal gear and air dry.
13. Inspect the rear internal teeth for the following:
    • Chips
    • Cracks
    • Excessive wear
    • Metal debris embedded in teeth
14. Replace the rear internal gear if any of the above conditions are found.
    Fig 6: Identifying Rear Internal Gear Flange & Rear Internal Gear

    Courtesy of SUZUKI OF AMERICA CORP.
15. Install a rear internal gear flange retaining ring (548).
16. Install the rear internal gear flange (547) in the rear internal gear (536).
17. Install the other rear internal gear flange retaining ring (548).
18. If the rear sun gear bushing is not within specifications or any of the above conditions are found, replace the rear sun gear.
    Fig 7: Measuring Front Carrier Bushing Inner Diameter

    Courtesy of SUZUKI OF AMERICA CORP.
19. Clean the front carrier assembly (542) and air dry. Ensure to remove all solvent in the pinion gears.
20. Inspect the front carrier assembly pinion teeth for the following conditions:
    • Chips
    • Cracks
    • Excessive wear
    • Metal debris embedded in teeth
21. Inspect for missing washers on both sides of the pinion gears.
22. Inspect the front carrier bushing for scoring or excessive wear.
23. Using J 45185 and a micrometer measure the front carrier bushing inner diameter (A). Measure in three locations and take the average.

    Specification 

    Front carrier bushing: 30.056-30.132 mm (1.183-1.186 in) 

24. If the front carrier bushing is not within specifications or any of the above conditions are found, replace the front carrier assembly.
    Fig 8: Measuring Front Sun Gear Bushing Diameter

    Courtesy of SUZUKI OF AMERICA CORP.
25. Clean the front sun gear (544) and air dry.
26. Inspect the front sun gear teeth for the following conditions:
    • Chips
    • Cracks
    • Excessive wear
    • Metal debris embedded in teeth
27. Inspect the rear sun gear teeth for the following:
    • Chips
    • Cracks
    • Excessive wear
    • Metal debris embedded in teeth
28. Inspect the front sun gear shaft for excessive wear or scoring at the front carrier assembly bushing area.
29. Using J 45185 and a micrometer measure the bushing inner diameter (A). Measure in three locations and take the average.

    Specification 

    Front sun gear bushing: 22.200-22.276 mm (0.874-0.877 in) 

30. If the front sun gear bushings are not within specifications or any of the above conditions are found, replace the front sun gear.
    Fig 9: Measuring Rear Sun Gear Bushing Diameter

    Courtesy of SUZUKI OF AMERICA CORP.
31. Inspect the bushing for scoring or excessive wear.
32. Using J 45185 and a micrometer measure the rear sun gear bushing inner diameter (A). Measure in three locations and take the average.

    Specification 

    Rear sun gear bushing: 22.200-22.276 mm (0.874-0.877 in)