Diesel Data: Automotive Repair
Home >> Suzuki >> 1997 >> Esteem GLX Plus L4-1.6L >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Clutch >> Service and Repair >> Overdrive Clutch

Overdrive Clutch





PRELIMINARY CHECK





1. Measure piston stroke.
(1) Install forward clutch assembly and overdrive/coast clutch assembly to transmission rear cover.
2. Measure overdrive clutch piston stroke while applying and releasing compressed air (400 - 800 kPa, 57 - 113 psi) through oil hole (A) by using Special Tools (A): 09900-20606 and (B): 09900-20701, or equivalent.
Specified piston stroke: 0.75 - 1.05 mm (0.03 - 0.041 inch)
If piston stroke exceeds specified value, disassemble and inspect inner parts.





3. Measure coast clutch piston stroke while applying and releasing compressed air (400 - 800 kPa, 57 - 113 psi) through oil hole by) by using Special Tools (A): 09900-20606 and (B): 09900-20701, or equivalent.
Specified piston stroke: 2.68 - 3.02 mm (0.106 - 0.119 inch)
If piston stroke exceeds specified value, disassemble and inspect inner parts.

DISASSEMBLY





1. Remove flanges, discs and plate of overdrive clutch by removing snap ring in following order. (1) Flange -> (2) Disc -> (3) Plate -> (4) Disc -> (5) Flange.

NOTE: Measure thickness of removed flange (1) and record for reference of piston stroke confirmation.





2. Remove overdrive clutch apply tube by removing snap ring.





3. Remove flanges, discs and plate of coast clutch by removing snap ring in following order. (1) Flange -> (2) Disc -> (3) Plate -> (4) Disc -> (5) Flange.

NOTE: Measure thickness of removed flange (1) and record for reference of piston stroke confirmation.





4. Using Special Tool (A): 09926-98310, or equivalent and hydraulic press, compress overdrive clutch return spring and remove snap ring.


CAUTION: Be careful when applying pressure, for overpressure will cause plate section of overdrive clutch return spring to deform.

5. Remove overdrive clutch return spring.





6. install forward clutch assembly, coast clutch piston with overdrive clutch piston installed.
7. Remove coast clutch piston with O-rings installed using compressed air (57 - 113 psi) through oil hole (A).
8. Remove O-rings from coast clutch piston.

NOTE: Never reuse O-rings after removal.





9. Remove overdrive clutch piston with O-rings installed using compressed air (57 - 1 13 psi) through oil hole (A).
10. Remove O-rings from overdrive clutch piston.

NOTE: Never reuse O-rings after removal.

INSPECTION





1. Check that sliding surfaces of discs, plates and flanges 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 overdrive clutch return spring.
Specified value: 18.9 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 piston clockwise and counterclockwise. (i.e., check that ball is free.)

ASSEMBLY





1. Apply A/T fluid to new O-rings.
2. Install new O-rings to pistons.
3. Set coast clutch piston to overdrive clutch piston by pushing with fingers.
4. Press overdrive clutch and coast clutch piston to overdrive clutch drum.

NOTE: Make sure that O-rings are not twisted or deviated from position during insertion of piston.





5. Using Special Tool (A): 09926-98310, or equivalent, and hydraulic press, compress overdrive clutch return spring and install snap ring.

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 overdrive clutch return spring at its retainer section.

CAUTION: Be careful when applying pressure, for overpressure will cause plate section of spring to deform.

6. Select and measure correct thickness of coast clutch flange

Available clutch flange size (thickness)
3.6 mm (0.142 inch)
3.8 mm (0.150 inch)
4.0 mm (0.157 inch)





7. Install flanges, discs and plate of coast clutch in following order. (1) Flange -> (2) Disc -> (3) Plate -> (4) Disc -> (5) Flange.

NOTE: Be sure to confirm that flat section of flange (5) selected in Step 6 faces toward piston side and also that flange (1) faces toward upper side.

8. Install snap ring.

NOTE: Check to make sure that opening end of ring is not aligned with groove section of drum.





9. Install overdrive clutch apply tube.
10. Select and measure correct thickness of overdrive clutch flange (flange (5) in Step 11).

Available clutch flange size (thickness)
3.6 mm (0.142 inch)
3.8 mm (0.150 inch)
4.0 mm (0.157 inch)

11. Install flanges, discs and plate of overdrive clutch in following order. (1) Flange -> (2) Disc -> (3) Plate -> (4) Disc -> (5) Flange.

NOTE: Be sure to confirm that flat section of flange (5) selected in Step 10. faces toward piston side and also that flange (1) faces toward upper side.





12. Install snap ring.

NOTE: Check to make sure that opening end of ring is not aligned with groove section of drum.

13. Install forward clutch assembly and overdrive direct multiple D clutch assembly to transmission rear cover.





14. Measure overdrive clutch piston stroke again, using Special Tools (A): 09900-20606 and (B): 09900-20701, or equivalent.

Specified piston stroke: 0.75 - 1.05 mm (0.03 - 0.041 inch)





15. Measure coast clutch piston stroke again, using Special Tools (A): 09900-20606 and (B): 09900-20701, or equivalent.

Specified piston stroke: 2.68 - 3.02 mm (0.106 - 0.119 inch)

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