Suzuki XL7 2007 Service Manual page 1681

Forward and Direct Clutch Assembly
Assemble
Reference: "Forward and Direct Clutch Assembly
Disassemble".
Special tool
J 23327 Clutch Spring Compressor
J 25024-A Servo Piston/Clutch Spring Compressor
J 28585 Snap Ring Remover
J 45186 Forward and Direct Clutch Spring
Compressor
NOTE
Soak the new clutch discs in automatic
transmission fluid for at least 2 hours before
installation.
1. Inspect the clutch plates for being worn or burnt.
Replace the plates if worn or burnt.
2. Shake the piston to be sure the ball check valve is
free.
WARNING
!
Wear safety glasses when using compressed
air in order to prevent eye injury.
3. Apply compressed air to the ball check valve to be
sure it is not leaking.
4. Inspect the O-ring grooves in the pistons for nicks or
scratches.
5. Inspect the clutch plate lugs in the forward clutch
piston for grooves.
6. Replace the piston if faulty.
Automatic Transmission:
7. Clean the forward and direct clutch housing
assembly and air dry. Ensure to remove all solvent
from the oil passages.
8. Inspect the forward and direct clutch housing
assembly for the following conditions:
– Input shaft bearing and bushing areas for
excessive wear or damage
– Rear support bearing surface for excessive wear
or damage
– Piston bores for nicks, grooves or excessive wear
– Clutch plate lugs for grooves that will prevent the
clutch plates from sliding
9. Replace the forward and direct clutch housing if any
of the above conditions are found.
10. Apply automatic transmission fluid to the new
forward clutch piston seals.
11. Install the forward clutch piston inner seal (564) and
the forward clutch piston outer seal (566) onto the
forward clutch piston (565).
12. Apply automatic transmission fluid to the inner
surface of the forward clutch drum.
5A-271