Direct Clutch & Output Shaft Assembly Disassembly and Reassembly - Suzuki Jimny Workshop Manual
5A
Direct Clutch & Output Shaft Assembly Disassembly and Reassembly
Disassembly
1)
Remove 2 seal rings (1) from output shaft (2).
2)
Compress snap ring (1) and remove ring gear (2) from output shaft (3).
3)
Remove snap ring (1).
4)
Remove direct clutch hub (1), bearing race (2) and bearing (3) from output shaft (4).
5)
Remove direct clutch assembly (1), bearing (2) and bearing race (3) from output shaft (4).
6)
Remove 2 seal rings (1) from intermediate shaft (2).
7)
Remove snap ring (1) from intermediate shaft (2).
8)
Remove direct clutch disc set (separator plate (1), 4 friction discs (2) and 4 friction plates (3)) from intermediate shaft (4).
9)
Using special tool and hydraulic press, compress direct clutch piston return spring (1) and remove snap ring (2) from intermediate shaft (3).
10)
Remove direct clutch balancer (4) and direct clutch piston return spring (1) from intermediate shaft (3).
11)
Blow air into oil passage (1) in intermediate shaft (2) to remove direct clutch piston (3) from intermediate shaft (2).
12)
Remove O-ring (4) from intermediate shaft (2).
Reassembly
1)
After applying A/T fluid to O-ring (1), install it to intermediate shaft (2).
2)
Install direct clutch piston (3), direct clutch piston return spring (4) and direct clutch balancer (5) to intermediate shaft (2).
NOTE:
Apply A/T fluid to seals (6) of direct clutch piston and direct clutch balancer.
3)
Using special tool and hydraulic press, compress direct clutch piston return spring (1) and install new snap ring (2) to intermediate shaft (3).
4)
Install direct clutch disc set (4 friction plates (1), 4 friction discs (2) and separator plate (3)) to intermediate shaft (4).
5)
Install new snap ring (1) to intermediate shaft (2).
6)
Check piston stroke of direct clutch referring to
Direct Clutch & Output Shaft Assembly Inspection
.
7)
After applying A/T fluid to 2 new seal rings (1), install them to intermediate shaft (2).
8)
Install bearing race (1), bearing (2) and direct clutch assembly (3) to output shaft (4).
9)
Install bearing (1), bearing race (2) and direct clutch hub (3) to output shaft (4).
10)
Install new snap ring (1) to output shaft (2).
11)
Compress snap ring (1) and install ring gear (3) to output shaft (2).
12)
After applying A/T fluid to new 2 seal rings (1), install them to output shaft (2).