Suzuki XL7 2007 Service Manual page 1684

5A-274 Automatic Transmission:
28. Install the forward clutch housing thrust bearing race
(568) 0.81 mm (0.032 in) thickness and the forward
clutch housing thrust bearing (569).
29. Apply automatic transmission fluid to the new input
shaft O-ring seal (570).
30. Install the new input shaft O-ring seal (570) into the
groove of the forward and direct clutch housing
assembly - with input shaft (567).
Reference: "Direct Clutch Piston Travel Check".
Reference: "Forward Clutch Piston Travel Check".
Direct Clutch Piston Travel Check
Reference: "Forward and Direct Clutch Assembly
Assemble".
Special tool
J 45200 Dial Indicator Set
J 45166 Dial Indicator Extension Rod - 8 inch"
1. Install the forward and direct clutch assembly (23)
onto the transmission case cover (19).
2. Remove the inner forward clutch accumulator cover
bolt/screw (617) from the forward clutch accumulator
assembly. Install J 45166 (2) in place of the
removed bolt.
3. Assemble J 45200 (3) and J 45166 (2) onto the
transmission case cover (19).
4. Install dial indicator extension - OTC # 222545 or
equivalent (4) on the dial indicator plunger.
5. Place the dial indicator plunger on the piston as
shown and set the dial indicator to zero.
6. Cover the forward clutch accumulator housing (1)
with a shop rag to prevent fluid from spraying out the
top of the accumulator housing when compressed
air is applied to the passage (C2).
WARNING
!
When you use compressed air in order to
clear fluid passages and to dry parts, always
aim the air pressure away from face and
eyes. Always wear adequate eye protection
in order to avoid injury from dirt and debris
that may adhere to parts.
7. Apply compressed air to the C2 fluid passage in the
case and measure the direct clutch piston stroke.
Specification
Direct clutch piston stroke: 1.49-1.91 mm (0.059-
0.075 in)
8. If the piston stroke is not within specifications,
replace the direct clutch backing plate with the
correct thickness. Refer to "Transmission Clearance
Specifications", Available Direct Clutch Backing
Plate Thickness.
Reference: "Forward and Direct Clutch Assembly
Installation".