Automatic Transmission: Overhaul Suzuki Forenza I

Transaxle Holding Fixture Assembly Disassembly and Assembly

Tools Required

DW260-020 Transaxle Holding Fixture

Scheme 58

1. Install the transaxle support fixture DW260-020 onto the transaxle.
2. Torque the support fixture bolts to 11 N.m (98 lb-in).
3. Position the transaxle with the rear cover facing up.

Scheme 59

Scheme 60

Scheme 61

1. Remove the oil pan bolts and oil pan.
2. Remove the oil pan gasket.
3. Remove valve body fixing bolts and transaxle input speed sensor bolt on the valve body.
4. Remove the holder for the transaxle input speed sensor.
5. Tilt the valve body.
6. Remove the fastening screw for the output speed sensor under the valve body assembly.
7. Lever the cable out of the retaining clip and pull out the output speed sensor.
8. Installation should follow the removal procedure in the reverse order.

Scheme 62

Scheme 63

1. Remove the valve body assembly. Refer to «Valve Body Disassembly and Assembly»(ref-257093-S34192662682007062900000) .
2. Pull out sealing sleeve (brake C) with a kind of nail.
3. Turn transaxle by 90°.
4. Remove the rear cover bolts.
5. Hit the rear cover rightly.
6. Remove the cover.
7. Installation should follow the removal procedure in the reverse order.

Clutch B/E Disassembly and Assembly

Tools Required

DW260-140 Clutch B Stop Ring Remover/Installer

DW260-150 Clutch E Stop Ring Remover/Installer

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

1. Remove the rear cover. Refer to «Rear Cover Disassembly and Assembly»(ref-257093-S24282747102007062900000) .
2. Remove the two sealing rings (clutch B/E).
3. Take out input shaft with clutch B/E.
4. Remove needle bearing and thrust washer.
5. Remove shim.
6. Take out the retaining snap ring.
7. Take out the piston B.
8. Remove disc set B.
9. Take out the piston rings.
10. Remove inner disc carrier E and needle roller thrust bearing.
11. Take out the snap ring.
12. Remove disc set E.
13. Press down cup spring (clutch E) with cup spring press fixture.
14. Remove the split stop ring.
15. Remove the oil dam and cup spring.
16. Pull the O-ring off the oil dam.
17. Press down cup spring (clutch B) with cup spring press fixture.
18. Remove the split stop ring.
19. Remove the cup spring.
20. Installation should follow the removal procedure in the reverse order.

Brake C/D Disassembly and Assembly

Tools Required

DW260-160 Brake C/D Snap Ring Remover/Installer

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Take snap ring out of transaxle housing.
2. Release cylinder with piston C by applying compressed air to the feed bore.
3. Remove cylinder with piston C.
4. Take disc carrier C/D and spring disc out of transaxle housing.
5. Release cylinder with piston D by applying compressed air to the feed bore.
6. Remove cylinder with piston D.
7. Separate between piston C and cylinder C.
8. Take snap ring out of brake C.
9. Remove the disc set C. Installation Notice Transaxle has two lined clutch discs and one steel clutch disc. The lined discs must be installed in such a way that the lining faces the steel disc. Insert the fitting keys into the appropriate grooves.
10. Turn the disc carrier C/D by 180°.
11. Using assembly bracket Press down cup spring and take out the snap ring.
12. Remove the disc set D.
13. Installation should follow the removal procedure in the reverse order.

Scheme 89

1. Remove the torque converter housing. Refer to «Torque Converter Housing Disassembly and Assembly»(ref-257093-S19462339572007062900000) .
2. Lift out the differential.
3. Installation should follow the removal procedure in the reverse order. Removal Notice Don't disassemble the differential to avoid incorrect operation.

Differential / Side Shaft Outer Race, Bearing Shim Disassembly and Assembly

1. Take out the outer race of the transaxle housing side.
2. Remove the bearing shim.
3. Take out the outer race of the torque converter housing side.