Mechanics

REPLACE THE CLUTCH

2006 Suzuki Forenza

Transmission problem
2006 Suzuki Forenza 4 cyl Two Wheel Drive Manual 50,122 miles

We have replaced clutches in Fords before but my neighbor said I have to drop the engine, etc to repair the clutch in a Suzuki. Is this true and is it much more difficult?
Avatar
Monicatzu
October 27, 2009.




Pressure Plate and Clutch Disc Removal and Installation
Removal
Disconnect the negative battery cable.
Remove the transaxle from the vehicle. Refer to " TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION : ".
Remove the pressure plate bolts and the pressure plate.
WARNING: Support the pressure plate when you remove the last bolt.

Fig. 12: Removing Pressure Plate Bolts And Pressure Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove the clutch disc from the flywheel.
Fig. 13: Removing Clutch Disc From Flywheel
Courtesy of SUZUKI OF AMERICA CORP.
Installation
Coat the spline on the clutch disc with multi-purpose grease.
Align the pressure plate and the clutch disc onto the flywheel using the clutch arbor J-42474.
Install the pressure plate bolts.
Tighten
Tighten the bolts to 15 N.M (11 lb-ft).
Remove the clutch arbor J-42474.
Install the transaxle into the vehicle. Refer to " TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION : ".
Connect the negative battery cable.

Transaxle Assembly Removal and Installation
Removal
Tools Required
DW110-060 Engine Support Fixture
DW260-010 Transaxle Support Fixture
Disconnect the negative battery cable.
Position the select lever park position.
Remove the battery. Refer to " BATTERY AND BATTERY TRAY REMOVAL AND INSTALLATION : ".
Install the engine support fixture DW110-060.
Fig. 151: Installing Engine Support Fixture DW110-060
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect the transaxle wiring harness from the transaxle.
Disconnect the park/neutral position switch electrical connector.
Fig. 152: Removing Shift Control Cable Clip
Courtesy of SUZUKI OF AMERICA CORP.
Remove the clips from the shift control cable and disconnect the shift control cable from the transaxle.
Fig. 153: Disconnecting Shift Control Cable From Transaxle
Courtesy of SUZUKI OF AMERICA CORP.
Remove the upper transaxle-to-engine bolts.
Fig. 154: Removing Upper Transaxle-To-Engine Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the left transaxle mounting bracket. Refer to " LEFT TRANSAXLE MOUNTING BRACKET REMOVAL AND INSTALLATION: ".
Fig. 155: Removing Left Transaxle Mounting Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Raise and suitably support the vehicle.
Drain the transaxle fluid.
Remove the oil cooler pipes from the transaxle. Refer to " OIL COOLER PIPES/HOSES REMOVAL AND INSTALLATION: ".
Fig. 156: Removing Oil Cooler Pipes From Transaxle
Courtesy of SUZUKI OF AMERICA CORP.
Remove the drive axle. Refer to " DRIVE AXLE ASSEMBLY REMOVAL AND INSTALLATION: For Automatic Transaxle".
Remove the starter motor. Refer to " STARTER REMOVAL AND INSTALLATION : ".
Remove the torque converter bolts.
Fig. 157: Removing Torque Converter Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Support the transaxle.
Remove the rear transaxle mounting bracket bolts (a) and damping block connection bolt and nut (b).
Fig. 158: Removing Rear Transaxle Mounting Bracket Bolts And Damping Block Connection Bolt And Nut
Courtesy of SUZUKI OF AMERICA CORP.
Support the transaxle assembly using the transaxle support fixture DW260-010.
Fig. 159: Supporting Transaxle Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove the lower engine-to-transaxle bolts.
Fig. 160: Removing Lower Engine-To-Transaxle Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the transaxle assembly.
Fig. 161: Removing Transaxle Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Installation
Install the transaxle into the vehicle.
Support the transaxle assembly using the transaxle support fixture DW260-010.
Fig. 162: Installing Transaxle Into Vehicle
Courtesy of SUZUKI OF AMERICA CORP.
Install the lower engine-to-transaxle bolts.
Tighten
Tighten the lower engine-to-transaxle bolts (a) to 75 N.M (55 lb-ft).
Tighten the lower engine-to-transaxle bolt (b) to 21 N.M (15 lb-ft).
Tighten the lower engine-to-transaxle bolt (c) to 31 N.M (23 lb-ft).
Fig. 163: Installing Lower Engine-To-Transaxle Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the rear transaxle mounting bracket bolts (a).
Tighten
Tighten the rear transaxle mounting bracket bolts (a) to 62 N.M (45 lb-ft).
Install the damping block connection bolt and nut (b).
Tighten
Tighten the damping block connection bolt and nut (b) to 68 N.M (50 lb-ft).
Fig. 164: Installing Damping Block Connection Bolt And Nut
Courtesy of SUZUKI OF AMERICA CORP.
Install the torque converter bolts.
Install the starter motor. Refer to " STARTER REMOVAL AND INSTALLATION : ".
Install the drive axle. Refer to " DRIVE AXLE ASSEMBLY REMOVAL AND INSTALLATION: For Automatic Transaxle".
Fig. 165: Installing Torque Converter Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the oil cooler pipes from the transaxle. Refer to " OIL COOLER PIPES/HOSES REMOVAL AND INSTALLATION: ".
Lower the vehicle.
Fig. 166: Installing Oil Cooler Pipes From Transaxle
Courtesy of SUZUKI OF AMERICA CORP.
Install the left transaxle mounting bracket. Refer to " LEFT TRANSAXLE MOUNTING BRACKET REMOVAL AND INSTALLATION: ".
Fig. 167: Installing Left Transaxle Mounting Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Install the upper transaxle-to-engine bolts.
Tighten
Tighten the upper transaxle-to-engine bolts to 75 N.M (55 lb-ft).
Fig. 168: Installing Upper Transaxle-To-Engine Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the clips to the shift control cable and connect the shift cable.
Fig. 169: Installing Clips To Shift Control Cable And Connecting Shift Cable
Courtesy of SUZUKI OF AMERICA CORP.
Install the park/neutral position switch electrical connector.
Connect the transaxle wiring harness to the transaxle.
Fig. 170: Connecting Transaxle Wiring Harness To Transaxle
Courtesy of SUZUKI OF AMERICA CORP.
Remove the engine support fixture DW110-060.
Install the battery. Refer to " BATTERY AND BATTERY TRAY REMOVAL AND INSTALLATION : ".
Add the transaxle fluid. Refer to " TRANSAXLE FLUID LEVEL CHECKING PROCEDURE: ".
Connect the negative battery cable.

Dave H
Apr 30, 2010.


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