Fluid Pump Installation

Reference: SECOND COAST CLUTCH PISTON TRAVEL MEASUREMENT .

Reference: SECOND COAST, SECOND CLUTCH HUB AND SECOND CLUTCH SPRAG ASSEMBLE .

Special Tool 

J 36850 Transjel Lubricant 

J 45053 Universal Clamp Press 

Fig 1: Identifying Coast Clutch Hub Thrust Washer & Second Coast Clutch Spring

Courtesy of SUZUKI OF AMERICA CORP.

1. Apply J 36850 to the coast clutch hub thrust washer (226).
2. Install the coast clutch hub thrust washer (226) with the flat surface facing up, and with the tangs engaged into the second coast clutch spring (224).
   Fig 2: Identifying Second Coast Clutch Hub & Sprag Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
3. While holding the second coast clutch hub and sprag assembly (11) together, install into the fluid pump assembly.
   Fig 3: Identifying Distance From Bottom Of Straight Edge & Fluid Pump Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
4. Place a straight edge on top of the second clutch sprag outer race thrust washer.
5. Measure the distance (b) from the bottom of the straight edge and the fluid pump assembly.

   Specification 

   Installed height: 51.09 - 51.71 mm (2.011 - 2.036 in) 

6. If the installed height is greater than specifications, the second coast clutch hub did not clear all the second clutch fiber plates. Index again the clutch hub and plates until within specifications.
   Fig 4: Installing Fluid Pump Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
7. Rotate the transmission assembly as shown.
8. Install the J 45053 on the fluid pump assembly.
   • Do not allow the second clutch sprag assembly to separate from the clutch plates.
   • Back out the forcing screw of the J 45053 to ensure, ample clearance of the input shaft.
9. Install the fluid pump assembly.
   • Do not allow the input shaft splines to touch the bushings in the fluid pump assembly.
   • Align the holes of the fluid pump assembly to the transmission case.
   • Do not allow the second clutch sprag assembly to separate from the clutch plates.
10. Lightly press the fluid pump body into the transmission case assembly in order to seat the fluid pump assembly in place.
    Fig 5: Identifying Fluid Pump To Case Bolt

    Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Do not use bolts longer than 28 mm. Using bolts longer than 28 mm will cause internal damage to the transmission.
11. Install the 8 - M8 x 1.25 x 28 mm fluid pump to case bolts (5) and hand tighten.
    Fig 6: Identifying Tightening Sequence Of Fluid Pump To Case Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
12. Rotate the transmission assembly so that the fluid pump assembly is facing up.
    CAUTION: Refer to FASTENER NOTICE .
13. Tighten the fluid pump to case bolts in the correct sequence.

    Tightening torque 

    Tighten the fluid pump to case bolts to 25 N.m (18 lb ft)  .

    Reference: CONTROL VALVE BODY ASSEMBLY INSTALLATION .