Reverse Clutch
Preliminary CheckMeasure piston stroke.
1. Remove sun gear input flange (1) with thrust washer (2) installed by removing retainer ring (3).
2. Remove input shaft (1) with thrust bearing race (3) and thrust needle roller bearing (2) installed.
3. Remove snap ring (2) of reverse clutch drum (1) 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 kgf/cm2, 57 - 113 psi) through oil hole section (A), using special tools.
Special tool
(A): 09900-20606
(B): 09900-20701
Specified value of piston stroke: 1.536 - 1.864 mm (0.037 - 0.062 inch)
NOTE:
^ To prevent air leakage from oil hole section (1) during piston stroke measurement with air nozzle gun, it is recommended to plug oil hole section around air nozzle gun with a clean cloth or the like because piston stroke cannot be measured otherwise.
^ If it is difficult to obtain correct specified value above, it is recommended to align plate (1) (Thickness: approximately 3 mm) with shape around oil hole section.
Disassembly
1. Remove reverse clutch drum (1) with bearing from oil pump body.
2. Remove sun gear input flange (2) with thrust washer (3) installed by removing retainer ring (4).
3. Remove No.3 clutch discs, clutch plates and cushion plate in the following order.
(1) Disc --> (2) Plate --> (3) Disc --> (4) Plate --> (5) Cushion plate
4. Remove reverse clutch return spring (1) by removing snap ring, using special tool and hydraulic press (2).
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 (1) by blowing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole section (A).
7. Remove two O-rings from piston.
NOTE: Never reuse removed O-rings.
Reassembly
1. Apply A/T fluid to new O-rings.
2. Install them to reverse clutch piston.
3. Press reverse clutch piston (1) into reverse clutch drum (2) 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 (1), using special tool and hydraulic press (2).
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 cushion plate, clutch plates and No.3 clutch discs in the following order.
(1) Cushion plate --> (2) Plate --> (3) Disc --> (4) Plate --> (5) Disc
NOTE: Check to make sure that flat end section of plate faces toward piston side.
7. Install sun gear input flange (2) with retainer ring (4).
8. Measure piston stroke.
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 (1) with grease.
"A": Grease (SUZUKI SUPER GREASE C) 99000-25030
12. Install thrust needle roller bearing to input shaft (3).
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 (2) with grease.
"A": Grease (SUZUKI SUPER GREASE C) 99000-25030
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 (1) with retainer ring (3).
17. Coat thrust washer (2) with grease.
18. Install thrust washer to reverse clutch assembly.
19. Coat race with thrust needle roller bearing (1) with grease.
"A": Grease (SUZUKI SUPER GREASE C) 99000-25030
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)
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) section) 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 of reverse clutch return spring height 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 (1) 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.