Oil Pump, 2ND Coast Brake and 2ND Brake Disassembly and Reassembly
Oil Pump, 2nd Coast Brake and 2nd Brake Disassembly and ReassemblyDisassembly
1. Remove 2nd coast brake thrust washer (1).
2. Using special tool and hydraulic press (1), compress 2nd brake piston return spring (2) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 in.) lower than snap ring groove and remove snap ring (3).
Special Tool (A): 09941-51010
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 2nd brake piston return spring to deform.
3. Remove retaining plate, friction plates and separator plates.
4. Using special tool and hydraulic press (1), compress 2nd coast brake piston return spring (2) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 in.) lower than snap ring groove and remove snap ring (3).
Special Tool (A): 09926-98350
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 2nd coast brake piston return spring to deform.
5. Remove 2nd coast brake piston return spring (2).
6. Remove 2nd coast brake piston (1) with O-rings by applying compressed air (400 - 800 kPa, 4 - 8 kg/cm2, 57 - 113 psi) from through oil hole (2).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.
7. Remove snap ring (1), using flat end rod or the like.
8. Remove retaining plate, friction plates, separator plates and cushion plate.
9. Remove 2nd brake piston return spring (2).
10. Remove 2nd brake piston (1) with O-rings applying compressed air (400 - 800 kPa, 4 - 8 kg/cm2, 57 - 113 psi) from through oil hole (2).
NOTE: If piston does not pop out, it is recommended to use needle-nose pliers for removal.
11. Remove stator shaft (1) by removing 14 bolts (2).
12. Remove oil pump plate (1), driven gear (2) and drive gear (3).
13. Remove O-ring.
14. Remove oil pump oil seal (1), using special tool.
Special Tool (A): 09913-50121
NOTE: Never reuse removed oil seal.
Reassembly
1. Press-fit new oil pump oil seal (1) using special tool and hammer and then apply grease to its lip portion.
Special Tool (A): 09913-85210
Grease 99000-25030SUZUKI Super Grease C
2. After applying A/T fluid to gears, install driven gear (1) and drive gear (2) to oil pump body (3) aligning marks on the gears.
3. Apply A/T fluid to new O-ring (4) and install it to oil pump body.
4. Install oil pump plate (5).
5. Install stator shaft (1) to oil pump body and tighten bolts (2) to specification.
Tightening torque
Oil pump cover bolts a: 6.5 Nm (0.65 kgf-m, 4.7 ft. lbs.)
Oil pump cover bolts b: 12 Nm (1.2 kgf-m, 8.7 ft. lbs.)
6. After applying A/T fluid to new O-rings and install it to 2nd brake piston.
7. Press 2nd brake piston into starter shaft.
NOTE: Do not twist or deviate O-rings during installation.
8. Install 2nd brake piston return spring.
9. Install cushion plate "C", separator plates "S", friction plates "F" and retaining plate "R" with flat end facing to friction plates side in the following order.
C --> S --> F --> S --> F --> S --> F --> S --> F --> R
10. Install snap ring.
NOTE: Make sure that opening end of ring is not aligned with groove section of starter shaft.
11. Apply A/T fluid to new O-rings and install them to 2nd coast brake piston.
12. Press 2nd coast brake piston (1) into starter shaft (2).
NOTE: Do not twist or deviate O-rings during installation.
13. Install 2nd coast brake piston return spring (1).
14. Using special tool and hydraulic press (2), compress 2nd coast brake piston return spring (1) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 in.) lower than snap ring groove and install snap ring (3).
Special Tool (A): 09926-98350
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of spring to deform.
NOTE:
^ When installing return spring, be careful so that return spring will not fall or tilt.
^ Do not align opening in snap ring with lug of 2nd coast brake piston return spring at its retainer section.
15. Install separator plates "S", friction plates "F" and retaining plate "R" in the following order.
S --> F --> S --> F --> R
NOTE: Make sure that 2nd brake piston return spring is inserted in 2nd coast brake retaining plate boss.
16. Using special tool and hydraulic press (1), compress 2nd brake piston return spring (2) until spring seat is pushed down to 1 - 2 mm (0.039 - 0.078 in.) lower than snap ring groove and install snap ring.
Special Tool (A): 09941-51010
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of spring to deform.
NOTE:
^ When installing return spring, be careful so that return spring will not fall or tilt.
^ Do not align opening in snap ring with lug of 2nd brake piston return spring at its retainer section.
17. Measure 2nd brake piston stroke again, using special tools.
If measured piston stroke exceeds specified value, check for an improper installation.
Special Tool
(A): 09900-20607
(B): 09900-20701
2nd brake piston stroke
Standard: 1.91 - 2.69 mm (0.075 - 0.106 in.)
18. Measure 2nd coast brake piston stroke, using special tools.
If measured piston stroke exceeds specified value, check for an improper installation.
Special Tool
(A): 09900-20607
(B): 09900-20701
2nd coast brake piston stroke
Standard: 0.82 - 1.66 mm (0.032 - 0.156 in.)
19. Install 2nd coast brake thrust washer (1).
If measured piston stroke exceeds specified value, check for an improper installation.
NOTE: Make sure lugs of 2nd coast brake thrust washer align with 2nd coast brake piston return spring.
