Input Shaft Oil Seal Replacement

CAUTION: Contamination and rough handling of the transaxle may cause premature wear, functional problems and damage to parts.

Thoroughly clean the exterior of the transaxle before disassembling it.
Keep workbench, tools and hands clean during the service operation.
Use special care when handling aluminum parts so as not to damage them.
Keep removed parts free of dust and other foreign matter.

Dismount CVT assembly, see CVT ASSEMBLY DISMOUNTING AND REMOUNTING .
Remove torque converter (1) from CVT assembly.

Fig 1: Removing Torque Converter From CVT Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft oil seal (1) by using flat-end screwdriver or the like (2).
CAUTION: CVT fluid may leak if the press-fitted part of the oil seal on the transaxle housing is damaged with the flat-head rod. Use the flat-head rod very carefully so that it will not scratch the press-fitted part of the oil seal.

Fig 2: Removing Input Shaft Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to new input shaft oil seal lip.
: Grease 99000-25030 (SUZUKI Super Grease C)
Using special tool, install input shaft oil seal (1) at specified position as shown in figure.
Special Tool
1. 09914-87910
2. 09922-59420
Input shaft oil seal installing depth

"a": 0.5 - 1.5 mm (0.020 - 0.059 in.)

Fig 3: Identifying Input Shaft Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Install torque converter (3) noting the following points.
CAUTION:
Failure to take proper precautions before and during installation of the torque converter can cause damage to other parts.
- Check the pump hub portion carefully before installing the torque converter. A torque converter having nicks, burrs or other damage at the pump hub portion will damage the oil seal, causing oil leaks. If the hub portion is damaged in any way, replace the torque converter.
- Do not drop the torque converter when installing it. If you drop the torque converter, it will damage the oil pump gear and cause a critical defect in the operation of the CVT.
- Install torque converter aligning projection (1) of torque converter and grooves (2) of oil pump.
- Install torque converter, using care not to damage input shaft oil seal.
- After installing torque converter (3), check that distance "a" is within specification.
  Torque converter installing position
  
  "a": More than 17.0 mm (0.669 in.)
- Check torque converter for smooth rotation.
  
  Fig 4: Identifying Flange Nut And CVT Case
  Courtesy of SUZUKI OF AMERICA CORP.
Remount CVT assembly, see CVT ASSEMBLY DISMOUNTING AND REMOUNTING .
Refill CVT fluid, see CVT FLUID CHANGE
Check CVT fluid level, see CVT FLUID CHECK .
After installation, check for CVT fluid leakage at each connection.