REMOVAL & INSTALLATION
Removal (Sidekick & X90)
Disconnect negative battery cable. Remove transmission and transfer case shift levers. Remove breather hose from clamp at rear of cylinder head. Release clamp at rear of intake manifold to free wiring harness. Disconnect harness connector. Remove starter motor. Remove transmission mounting bolts.
Raise vehicle and drain fluid from transfer case. Remove front and rear drive shafts. Disconnect clutch cable. Remove clutch housing lower plate. Remove center exhaust pipe. Remove engine-to-transmission mounting bolts and nuts. Disconnect speedometer cable.
Support transmission/transfer case assembly with floor jack. Remove rear engine mount crossmember. Move transmission/transfer case assembly to rear and lower. Remove wiring harness and breather hose.
If reusing pressure plate, mark pressure plate and flywheel for reassembly reference. Alternately loosen pressure plate attaching bolts until pressure plate is released. Remove clutch disc and pressure plate. See Fig. 1.
Fig. 1: Exploded View Of Clutch Assembly (Typical)
Courtesy of SUZUKI OF AMERICA CORP.
Check wear on facings of clutch disc by measuring depth of each rivet head. Minimum depth at any rivet is.02" (.5 mm). Replace clutch disc if not within specification.
Check diaphragm spring and pressure plate for wear and damage. If assembly is excessively worn or damaged, replace pressure plate. Check pilot bearing rotation. If roughness is felt, replace bearing. Inspect flywheel runout.
Clean flywheel and pressure plate of all oil, grease, and metal deposits. Inspect for damage, cracks or warpage. Remove slight surface scoring with sandpaper. Replace or repair as necessary.
Install clutch alignment tool. Position clutch disc on flywheel. If reusing pressure plate, install pressure plate on flywheel and align index marks. Tighten pressure plate-to-flywheel bolts to specification in a diagonal pattern. See TORQUE SPECIFICATIONS. Lightly coat input shaft splines with lithium grease. To complete installation, reverse removal procedure.