Clutch: Service and Repair

CLUTCH COVER, CLUTCH DISC AND FLYWHEEL





DISMOUNTING OF TRANSMISSION

Under Hood
1. Disconnect battery ground cable.
2. Remove clutch cable joint nut, joint pin from cable and then cable itself from bracket.
3. Undo wiring harness clamps and couplers.
4. Remove transmission fastening bolts.
5. Remove starter taking out its 2 bolts. Starting motor plate should also come down.
6. Remove exhaust manifold cover.
7. Remove exhaust No.1 pipe nuts.

On Lift





1. Drain transmission oil.
2. Remove engine under cover of left side.
3. Remove exhaust No. 1 pipe.
4. Remove gear shift control shaft bolt and nut, then detach control shaft from gear shift shaft.
5. Remove extension rod nut and then pull out rod with washers.





6. Remove clutch housing lower plate. Disconnect stabilizer joint from suspension arm.
7. Remove ball stud bolt from right and left knuckles, then disconnect each suspension arm.
8. By using large size screwdrivers, pull out drive shaft joints at differential side so as to release snap ring fitting of joint. (for LH drive shaft).





9. Remove center bearing support bolts and pull out center drive shaft from differential gear. (for RH drive shaft).
10. Remove transmission stiffener.
11. Remove transmission to engine bolt and nut.
12. Remove engine rear mounting bracket bolts.
13. Lower vehicle and support transmission with transmission jack.





14. Remove engine mounting LH No.1 bracket.
15. Other attached parts from transmission, if any.
16. Pull transmission out so as to disconnect input shaft from clutch disc and then lower it.

REMOUNTING





For remounting, reverse dismounting procedure. Use specified torque as given.
Tightening torque Transmission to engine bolts and nuts 90 Nm (9.0 kg-m 65.0 ft. lbs.)
Engine rear mounting bracket bolts 50 Nm (5.0 kg-m 36.5 ft. lbs.)
Exhaust No.2 pipe to No.1 pipe bolts 50 Nm (5.0 kg-m 36.5 ft. lbs.)
Center bearing support bolts 50 Nm (5.0 kg-m 36.5 ft. lbs.)
Exhaust No. 1 pipe to manifold nuts 50 Nm (5.0 kg-m 36.5 ft. lbs.)
Transmission case lower stiffener bolt 50 Nm (5.0 kg-m 36.5 ft. lbs.)
Ball stud bolt and nut 60 Nm (6.0 kg-m 43.5 ft. lbs.)
Extension rod nut 33 Nm (3.3 kg-m 24.0 ft. lbs.)
Gear shift control shaft bolt and nut 18 Nm (1.8 kg-m 13.0 ft. lbs.)
Stabilizer bar link nut 28 Nm (2.8 kg-m 20.5 ft. lbs.)

NOTE: Apply grease to gear shift control shaft bushes, however, DO NOT lubricate extension rod bush.

CAUTION:
^ Care should be taken not to scratch oil seal lip with drive shaft while raising transmission.
^ Do not hit drive shaft joint with hammer when installing it into differential gear.

- Push in left side drive shaft joint fully so as to snap ring of shaft engages with differential gear.





- Set each clamp for wiring securely.
- After connecting clutch cable, be sure to adjust its play properly.

Arm play "a": 0 - 2 mm (0 - 0.08 inch)
Pedal play "a": 15 - 20 mm (0.6 - 0.8 inch)

- Fill transmission with oil as specified.
- Connect battery and check function of engine, clutch and transmission.





REMOVAL
1. Hold flywheel stationary with special tool and remove clutch cover bolts, clutch cover and clutch disc.

Special Tool
(A): 09924-17810





2. Pull out input shaft bearing by using special tool and wrench.

Special Tool
(B): 09917-58010

INSPECTION
Input Shaft Bearing
Check bearing for smooth rotation and replace it if abnormality is found.





Clutch Disc
Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.

Rivet head depth "a": Standard 1.4 mm (0.06 inch)
Service limit 0.5 mm (0.02 inch)

Clutch Cover
1. Check diaphragm spring for abnormal wear or damage.
2. Inspect pressure plate for wear or heat spots.
3. If abnormality is found, replace it as assembly.
Do not disassemble it into diaphragm and pressure plate.

Flywheel
Check surface contacting clutch disc for abnormal wear or heat spots. Replace or repair as required.

INSTALLATION

NOTE: Before assembling, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.

1. Install flywheel to crankshaft and tighten bolts to specification.

Special Tool
(A): 09924-17810

Tightening Torque
(a): 78 Nm (7.8 kg-m, 56.5 ft. lbs.)

2. Using special tool, install input shaft bearing to flywheel.

Special Tool
(B): 09925-98210

3. Aligning clutch disc with flywheel center by using special tool, install clutch cover and bolts.

NOTE:
^ While tightening clutch cover bolts, compress clutch disc with special tool (clutch center guide) by hand so that disc is centered.
^ Tighten cover bolts little by little evenly in diagonal order.

Special Tool
(A): 09924-17810
(C): 09923-36330

Tightening Torque
(b): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)

4. Slightly apply grease to input shaft, then join transmission assembly with engine.

"A": SUZUKI SUPER GREASE I, 99000-25210

NOTE: Turn crankshaft a little through flywheel gear while inserting transmission input shaft to clutch disc until splines mesh.