Clutch replace

Tiny
DANKAT1966
  • MEMBER
  • 2003 SUZUKI AERIO
  • 4 CYL
  • 2WD
  • MANUAL
  • 178,000 MILES
My suzuki Aerio needs a clutch change. It is with a friend who has never worked on an Aerio before (works competently on Nissan z). We are trying to figure out how to drop the (manual) transmission - getting axle out etc. Suzuki technicians either do not want to divulge the process or state that they have not worked on many aerios before. Can anyone walk us through this step by step? Thanks.
Thursday, August 5th, 2010 AT 7:17 PM

5 Replies

Tiny
SATURNTECH9
  • MECHANIC
  • 30,869 POSTS
Here is the instructions for trans axle R&R and a video of the job being done on a similar car (the process is the same)

https://youtu.be/6N6b5F2ChyE

Transaxle Unit Dismounting and Remounting
Dismounting
Under hood
1. Disconnect battery ground cable.
2. Remove clutch operating cylinder from T/M with hose still attached.
3. Remove gear control cables.
4. Remove water intake pipe bolts.
5. Undo wiring harness clamps and connectors.
6. Remove ground cable from T/M.
7. Remove starting motor taking out its bolt and nut.
8. Remove transaxle fastening bolts.
9. Support engine by using lifting device.

On lift
1. Drain transaxle oil.
2. Remove engine under covers.
3. Remove exhaust No.1 pipe and exhaust No.2 pipe.
4. Remove lower stiffener.
5. Remove ball stud bolt form right and left knuckles, then disconnect each suspension arm.
6. Using flat head rod or the like (2), pull out drive shaft joint (1) at differential side so as to release snap ring fitting of joint (for LH drive shaft). Using plastic hammer (3), drive out drive shaft joint so as to release snap ring fitting of joint spline at center shaft (for RH drive shaft).
7. Remove center shaft support bolts (3) and remove center shaft support (2) with center shaft (1) from differential side gear.
8. Remove dynamic damper from engine rear mounting No.1 bracket.
9. Remove engine rear mounting from its bracket.
10. Remove engine rear mounting No.1 bracket with No.2 bracket.
11. Remove transaxle to engine bolts and nut.
12. Lower vehicle and support transaxle (2) with transmission jack.

13. Remove engine LH mounting with bracket (1).
14. Remove other attached parts from transaxle, if any.
15. Pull transaxle out so as to disconnect input shaft from clutch disc and then lower it.

Remounting

CAUTION:
Care should be taken not to scratch oil seal lip with drive shaft while raising transaxle.
Do not hit drive shaft joint with hammer when installing it into differential gear. For remounting, reverse dismounting procedure noting the following.
Push in drive shaft joints fully so as to engage snap ring of shaft with differential gear or center shaft.
Set each clamp for wiring securely.
Fill transaxle with oil as specified.
Connect battery and check function of engine, clutch and transaxle.
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Thursday, August 5th, 2010 AT 8:51 PM
Tiny
CHRISBURNS2009
  • MEMBER
  • 1 POST
  • 2003 SUZUKI AERIO
  • FWD
  • MANUAL
How do I drop the transmision in a 03 suzuki aerio sx to replace the throwout bearing?
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Friday, December 28th, 2018 AT 11:27 AM (Merged)
Tiny
KHLOW2008
  • MECHANIC
  • 41,814 POSTS
MANUAL TRANSAXLE UNIT DISMOUNTING
1. Disconnect battery ground cable.

2. Remove clutch operating cylinder from T/M with hose still attached.

3. Remove gear control cables.

4. Undo wiring harness clamps and connectors.

5. Remove ground cable from T/M.

6. Remove starting motor taking out its bolt and nut.

7. Remove exhaust No. 1 pipe bolts.

8. Remove transaxle fastening bolts.

9. Support engine by using lifting device.

10. Drain transaxle oil.

11. Remove engine under covers.

12. Remove exhaust No.1 pipe and exhaust No.2 pipe.

13. Remove lower stiffener.

14. Remove ball stud bolt form right and left knuckles, then disconnect each suspension arm.

15. Pull out drive shaft joint.

16. Remove center shaft support and center shaft from differential side gear.

17. Remove starter motor.

18. Remove dynamic damper from engine rear mounting No.1 bracket.

19. Remove engine rear mounting from its bracket.

20. Remove engine rear mounting No.1 bracket with No.2 bracket.

21. Remove transaxle to engine bolts and nut.

22. Lower vehicle and support transaxle (2) with transmission jack.

23. Remove engine LH mounting with bracket (1).

24. Remove other attached parts from transaxle, if any.

25. Pull transaxle out so as to disconnect input shaft from clutch disc and then lower it.

26. For remounting, reverse dismounting procedure.
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+2
Friday, December 28th, 2018 AT 11:27 AM (Merged)
Tiny
LAURA LOU LOWDEN
  • MEMBER
  • 1 POST
Let me ask you a question can you can you grease a throwout bearing and see if that helps not having to replace it is that possible
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Wednesday, January 30th, 2019 AT 10:49 AM
Tiny
DANNY L
  • MECHANIC
  • 5,648 POSTS
Hello, I'm Danny.

Unfortunately no. Throw out bearings are a sealed unit and cannot be greased. Hope this helps and thanks for using 2CarPros.
Danny-
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Wednesday, January 30th, 2019 AT 10:46 PM

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