Reverse Clutch

PRELIMINARY INSPECTION
Measure pack clearance.





1. Remove sun gear input flange with thrust washer installed by removing retainer ring.





2. Remove input shaft with thrust bearing race and thrust needle roller bearing installed.





3. Remove snap ring of reverse clutch drum with bearing.





4. Install sun gear input flange (thrust washer installed) with retainer ring.
5. Mount reverse clutch drum with bearing to oil pump body.
6. Measure piston stroke with compressed air (400 - 800 kPa, 4 - 8 kg/cm2,57 - 113 psi) through oil hole section (A), using special tools.
Special Tools
(A): 09900-20606
(B): 09900-20701
Specified value: 0.93 - 1.60 mm (0.037 - 0.062 inch)

NOTE:
^ To prevent air leakage from off hole section (A) during pack clearance measurement with air nozzle gun, it is recommended to plug on hole section around air nozzle gun with a clean cloth or the like because pack clearance cannot be measured otherwise.
^ If it is difficult to obtain correct specified value, it is recommended to align plate (Thickness: approximately 3 mm) with shape around off hole.

DISASSEMBLY





1. Remove reverse clutch drum with bearing from oil pump body.
2. Remove sun gear input flange with thrust washer installed by removing retainer ring.
3. Remove No. 3 clutch discs and clutch plates in following order.
(1) Disc -> (2) Plate -> (3) Disc -> (4) Plate





4. Remove reverse clutch return spring by removing snap ring, using special tool and hydraulic press.
Special Tool
(A): 09926-96010

NOTE: To prevent deformation of spring seat, it is recommended to compress spring seat until claw section of snap ring is free.





5. Mount reverse clutch drum with bearing to oil pump body.
6. Remove reverse clutch piston by blowing compressed air (400 - 800 kPa, 4 - 8 kg/cm2, 57 - 113 psi) through oil hole(A).
7. Remove two O-rings from piston.

NOTE: Never reuse removed O-rings.

INSPECTION





1. Check that sliding surfaces of disc and plate are not worn or burnt. If necessary, replace.

NOTE:
^ If disc lining is exfoliated or discolored, or part of printed numbers ((A)) is defaced, replace all discs.
^ Before assembling new discs, soak them in A/T fluid for at least two hours.





2. Measure height of reverse clutch return spring.
Specified value: 18.7 mm (0.74 inch)

NOTE: Do not apply excessive force when measuring spring height. Perform measurement at several points.





3. Check to make sure that ball makes creaking noise when shaking the reverse clutch piston. (i.e., check that ball is free.)
4. Check that there is no leakage by applying low-pressure air onto ball.





5. Check that outer surface of reverse clutch with bearing is not worn or burnt. If necessary, replace.

ASSEMBLY





1. Apply A/T fluid to new O-rings.
2. Install them to reverse clutch piston.
3. Press reverse clutch piston into reverse clutch drum with bearing with cup side up.

NOTE: Do not twist or deviate O-rings during installation.





4. Place reverse clutch return spring onto reverse clutch piston.
5. Install snap ring, using special tool and hydraulic press.
Special Tool
(A): 09926-96010

NOTE: To prevent spring seat deformation, be sure to keep clearance of 1 - 2 mm between return spring seat and snap ring.





6. Install clutch plates and No. 3 clutch discs in following order.
(1) Plate -> (2) Disc -> (3) Plate -> (4) Disc

NOTE: Check to make sure that flat end section of plate faces toward piston side.





7. Install sun gear input flange with retainer ring.
8. Measure pack clearance, referring to PRELIMINARY INSPECTION in REVERSE CLUTCH.
9. Remove reverse clutch from oil pump body.
10. Remove sun gear input flange by removing retainer ring.





11. Coat race with thrust needle roller bearing with grease.
Grease: 99000-25030 (SUZUKI SUPER GREASE C)
12. Install thrust needle roller bearing to input shaft.
Race with bearing dimension
Outside diameter: 31.1 mm (1.22 inch)
Inside diameter: 18.7 mm (0.74 inch)
Thickness: 2.6 mm (0.10 inch)
13. Coat thrust bearing race with grease.
Grease: 99000-25030 (SUZUKI SUPER GREASE C)
14. Install thrust bearing race to input shaft.
Race dimension
Outside diameter: 33.3 mm (1.31 inch)
Inside diameter: 21.7 mm (0.85 inch)
Thickness: 2.0 mm (0.08 inch)





15. Install input shaft to reverse clutch drum.
16. Install sun gear input flange with retainer ring.
17. Coat thrust washer with grease
Grease: 99000-25030 (SUZUKI SUPER GREASE C)
18. Install thrust washer to reverse clutch assembly.





19. Coat race with thrust needle roller bearing with grease.
Grease: 99000-25030 (SUZUKI SUPER GREASE C)
20. Install thrust needle roller bearing to reverse clutch assembly.
Race with bearing dimension
Outside diameter: 32.9 mm (1.30 inch)
Inside diameter: 18.8 mm (0.74 inch)
Thickness: 3.6 mm (0.14 inch)