Suzuki Grand Vitara JB416 / JB420. Manual — part 259
5B-32 Manual Transmission/Transaxle:
Special Tool
S5JB0A5208002
09900–06106
09913–50121
Snap ring pliers (closing
type)
Oil seal remover
09913–75810
09913–80113
Bearing installer
Bearing installer
09913–84510
09913–85210
Bearing installer
Bearing installer
09923–46020
09925–78210
Joint pipe
Spring pin remover (6 mm)
09930–30104
09940–51710
Sliding shaft
Bearing installer
09941–64511
Bearing and oil seal remover
(30 mm Min.)
)
Clutch: 5C-1
Transmission / Transaxle
Clutch
General Description
Clutch (Hydraulic Type) Construction
S5JB0A5301001
The clutch is a diaphragm-spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part, with
a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned on
the transmission input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries
the diaphragm spring in such a way that the peripheral
edge part of the spring pushes on the pressure plate
against the flywheel (with the disc in between), when the
clutch release bearing (incorporated in clutch operating
cylinder) is held back. This is the engaged condition of
the clutch.
Depressing the clutch pedal causes the release bearing
(incorporated in clutch operating cylinder) to advance
and pushes on the tips of the tapered fingers of the
diaphragm spring. When this happens, the diaphragm
spring pulls the pressure plate away from the flywheel,
thereby interrupting the flow of drive from flywheel
through clutch disc to transmission input shaft.
Clutch fluid is supplied from brake fluid reservoir.
Clutch fluid level can be checked by brake fluid level of
brake fluid reservoir.
1. Crankshaft
7. Release bearing
2. Flywheel
8. Input shaft bearing
3. Clutch disc
9. Input shaft
4. Pressure plate
10. Operating cylinder
5. Clutch cover
11. Clutch housing
6. Diaphragm spring
1
2
3
4
5
6
7
10
8
9
11
I5JB0A530001-01
5C-2 Clutch:
Component Location
Clutch Fluid Pipe and Hose Location
S5JB0A5303001
1
1
2
2
2
3
4
5
5
6
6
7
[A]
I5JB0A530002-03
[A]: Right-hand steering vehicle
3. Clutch fluid hose
6. Brake master cylinder reservoir
1. Clutch master cylinder
4. Clutch operating cylinder assembly
7. Clutch fluid pipe joint
2. Clutch fluid pipe
5. Clutch reservoir hose
Clutch: 5C-3
Diagnostic Information and Procedures
Clutch (Hydraulic Type) Symptom Diagnosis
S5JB0A5304001
Condition
Possible cause
Correction / Reference Item
Slipping
Improper clutch pedal free travel
Bleed air or replace master cylinder.
Worn or oily clutch disc facing
Replace disc.
Warped disc, pressure plate or flywheel
surface
Replace disc, clutch cover or flywheel.
Weakened diaphragm spring
Replace clutch cover.
Master cylinder piston or seal cup not
returning
Repair master cylinder.
Dragging clutch
Improper clutch pedal free travel
Bleed air or replace master cylinder.
Weakened diaphragm spring, or worn
spring tip
Replace clutch cover.
Rusted input shaft splines
Lubricate.
Damaged or worn splines of
transmission input shaft
Replace input shaft.
Excessively wobbly clutch disc
Replace disc.
Clutch facings broken or dirty with oil
Replace disc.
Fluid leakage
Repair or replace.
Clutch vibration
Glazed (glass-like) clutch facings
Repair or replace disc.
Clutch facings dirty with oil
Replace disc.
Release bearing slides unsmoothly
Replace clutch operating cylinder assembly.
Wobbly clutch disc, or poor facing
contact
Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose
Replace disc.
Distorted pressure plate or flywheel
surface
Replace clutch cover or flywheel.
Weakened or loosened engine mounting
bolt or nut
Retighten or replace mounting.
Noisy clutch
Worn or broken release bearing
Replace clutch operating cylinder assembly.
Input shaft front bearing worn down
Replace input shaft bearing.
Excessive rattle of clutch disc hub
Replace disc.
Cracked clutch disc
Replace disc.
Pressure plate and diaphragm spring
rattling
Replace clutch cover.
Grabbing clutch
Clutch disc facings soaked with oil
Replace disc.
Clutch disc facings excessively worn
Replace disc.
Rivet heads showing out of facing
Replace disc.
Weakened torsion springs
Replace disc.
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