Get Clutch Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

CLUTCH 7C-1

SECTION 7C

CLUTCH

CONTENTS

GENERAL DESCRIPTION 7C- 2. . . . . . . . . . . . . .

DIAGNOSIS 7C- 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 7C- 5. . . . . . . . . . . . . . . .

MAINTENANCE SERVICE 7C- 5. . . . . . . . .

Clutch Pedal 7C- 5. . . . . . . . . . . . . . . . . . .

Clutch Cable 7C- 6. . . . . . . . . . . . . . . . . . .

UNIT REPAIR OVERHAUL 7C- 7. . . . . . . . . . . .

Clutch Cover, Clutch Disc and

Flywheel 7C- 7. . . . . . . . . . . . . . . . . . . . . . . .

Clutch release system

(For 5-speed Transmission) 7C-11. . . . . . . .

REQUIRED SERVICE MATERIALS 7C-14. . . . .

SPECIAL TOOLS 7C-14. . . . . . . . . . . . . . . . . . . .

7C-2 CLUTCH

GENERAL DESCRIPTION

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 is held back. This is the en-

gaged condition of the clutch.

Depressing the clutch pedal causes the release bear-

ing 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.

1. Clutch cover

2. Pressure plate

3. Diaphragm spring

4. Release bearing

5. Release shaft

Apply lithium grease 99000-25010

to pin for release bearing

6. Transmission right case

7. Clutch disc

8. Torsional spring

9. Input shaft bearing

10. Input shaft

Apply lithium grease 99000-25210

to spline part

11. Crankshaft

12. Flywheel

13. Flywheel bolt

14. Clutch cover bolt

: Tightening Torque

[5-speed Manual Transmission]

CLUTCH 7C-3

1. Clutch cover

2. Pressure plate

3. Diaphragm spring

4. Release bearing

5. Release shaft

Apply lithium grease 99000-25010

to pin for release bearing

6. Transmission lower case

7. Clutch disc

8. Torsional spring

9. Input shaft bearing

10. Input shaft

Apply lithium grease 99000-25210

to spline part

11. Crankshaft

12. Flywheel

13. Flywheel bolt

14. Clutch cover bolt

: Tightening Torque

[4-speed Manual Transmission]

7C-4 CLUTCH

DIAGNOSIS

Condition

Possible Cause Correction

Slipping D Improper clutch pedal free travel

D Worn or oily clutch disc facing

D Warped disc, pressure plate or flywheel surface

D Weakened diaphragm spring

D Rusted clutch cable

Adjust free travel.

Replace disc.

Replace disc, clutch cover or flywheel.

Replace clutch cover.

Replace cable.

Dragging clutch D Improper clutch pedal free travel

D Weakened diaphragm spring, or worn spring tip

D Rusted input shaft splines

D Damaged or worn splines of transmission input

shaft

D Excessively wobbly clutch disc

D Clutch facings broken or dirty with oil

Adjust free travel.

Replace clutch cover.

Lubricate.

Replace input shaft.

Replace disc.

Clutch vibration D Glazed (glass-like) clutch facings

D Clutch facings dirty with oil

D Release bearing slides unsmoothly on input

shaft bearing retainer

D Wobbly clutch disc, or poor facing contact

D Weakened torsion springs in clutch disc

D Clutch disc rivets loose

D Distorted pressure plate or flywheel surface

D Weakened or loosened engine mounting

bolt or nut

Repair or replace disc.

Replace disc.

Lubricate or replace input shaft

bearing retainer.

Replace disc.

Replace clutch cover or flywheel.

Retighten or replace mounting.

Noisy clutch D Worn or broken release bearing

D Input shaft front bearing worn down

D Excessive rattle of clutch disc hub

D Cracked clutch disc

D Pressure plate and diaphragm spring rattling

Replace release bearing.

Replace input shaft bearing.

Replace disc.

Replace clutch cover.

Grabbing clutch D Clutch disc facings soaked with oil

D Clutch disc facings excessively worn

D Rivet heads showing out of facing

D Weakened torsion springs

Replace disc.

ON-VEHICLE SERVICE

MAINTENANCE SERVICE

CLUTCH PEDAL

CLUTCH PEDAL HEIGHT

Measure pedal height difference “a” using measure (3) and adjust

clutch pedal (1) height so that it becomes almost same as brake

pedal (2) height.

Height difference “a”: 0 mm (0 in.)

If clutch pedal height is not as specified above, adjust it by turning

pedal stopper bolt (4).

Be sure to tighten lock nut (5) after adjustment.

Tightening Torque

(a): 5.5 N·m (0.6 kg-m, 4.5 lb-ft)

CLUTCH PEDAL FREE TRAVEL

1) Depress clutch pedal (1), stop the moment clutch resistance is

felt, and measure distance (clutch pedal free travel). Free travel

should be within the following specification.

Pedal free travel “b”: 15 – 20 mm (0.6 – 0.8 in.)

2) If free travel is out of specification, adjust it with cable joint nut

(3).

Release arm (4) free travel “c”:

For 5-speed manual transmission : 0 – 2 mm (0 – 0.08 in.)

For 4-speed manual transmission : 2 – 4 mm

(0.08 – 0.16 in.)

3) After checking clutch pedal free travel, also check clutch for

proper function with engine running.

1. Clutch cable

2. Joint pin

CLUTCH 7C-5

CLUTCH CABLE

REMOVAL

1) Disconnect negative cable at battery.

2) Remove clutch cable joint nut (1).

3) Remove joint pin (2) from clutch release arm (3).

4) Remove 2 bolts at dash panel.

INSPECTION

Inspect clutch cable and replace it for any of the following condi-

tions.

D Excessive cable friction

D Frayed cable

D Bent or kinked cable

D Broken boots

D Worn end

INSTALLATION

Reverse removal procedure for installation noting the following.

D Apply grease to cable end hook and also joint pin before instal-

ling cable.

Grease 99000-25010

D Screw in joint nut and adjust free travel of pedal to specification

by turning nut.

D Check clutch for proper function with engine running.

D For 4-speed transmission, the clearance between clutch cable

(1) and body must be more than 15 mm (0.59 in.).

7C-6 CLUTCH

1. Clutch disc

Apply lithium grease 99000-25210 to

spline of input shaft

2. Clutch cover

3. Bolt

4. Release bearing

Apply lithium grease 99000-25010 to

joint of clutch release shaft and inside of bearing

5. Clutch release shaft

Apply lithium grease 99000-25010 to

joint of release bearing

6. Spring pin

7. Clutch release shaft No.1 bush.

Apply lithium grease 99000-25010 to inside

8. Return spring

9. Clutch release shaft No.2 bush

Apply lithium grease 99000-25010 to inside

10. Clutch release shaft seal

Apply lithium grease 99000-25010 to inside

11. Lock washer

12. Clutch retainer spring (2 pcs.)

13. Cover reamer bolt (2 pcs.)

14. Release bearing retainer

: Tightening Torque

[5-speed Manual Transmission] [4-speed Manual Transmission]

DISMOUNTING / REMOUNTING

Dismount or mount transmission with engine referring to SECTION

6A, and separate or combine transmission and engine.

REMOVAL

1) Hold flywheel stationary with special tool and remove clutch

cover bolts (1), clutch cover (2) and clutch disc.

Special Tool

(A): 09924-17810

CLUTCH 7C-7

UNIT REPAIR OVERHAUL

CLUTCH COVER, CLUTCH DISC AND FLYWHEEL

2) Pull out input shaft bearing (1) from flywheel (2) using special

tool and wrench.

Special Tool

(B): 09917-58010 (For 5-speed transmission)

(B): 09921-20200 (For 4-speed transmission)

INSPECTION

Input Shaft Bearing

Check input shaft bearing (1) for smooth rotation and replace it if

abnormality is found.

Clutch Disc

Measure depth of rivet head depression, i.e. distance between rivet

head and facing surface. If depression is found to have reached

service limit at any of holes, replace disc assembly.

Rivet head depth

Standard: 1.2 mm (0.05 in.)

Service limit: 0.5 mm (0.02 in.)

Clutch Cover

D Check diaphragm spring (1) for abnormal wear or damage.

D Inspect pressure plate (2) for wear or heat spots.

D If abnormality is found, replace it as assembly. Do not disas-

semble it into diaphragm and pressure plate.

Flywheel

Check surface contacting clutch disc for abnormal wear or heat

spots. Replace or repair as required.

7C-8 CLUTCH

INSTALLATION

NOTE:

Before assembling, make sure that flywheel surface and pres-

sure plate surface have been cleaned and dried thoroughly.

1) Install flywheel (1) to crankshaft and tighten bolts (2) to specifi-

cation.

Special Tool

(A): 09924-17810

Tightening Torque

(a): 42 N

m (4.2 kg-m, 30.5 lb-ft)

2) Using special tool, install a new input shaft bearing to flywheel

(1).

Special Tool

(B): 09925-98210 (For 5-speed transmission)

(B): 09943-88210 (For 4-speed transmission)

3) Aligning clutch disc to flywheel center using special tool, install

clutch cover (1) and bolts. Then tighten bolts to specification.

[4-speed Transmission]

NOTE:

D While tightening clutch cover bolts, compress clutch

disc with special tool by hand so that disc centered.

D For 4-speed manual transmission, be sure to use 2 ream-

er bolts (2) as shown.

Special Tool

(A): 09924-17810

(C): 09923-36330

Tightening Torque

(b): 23 N

m (2.3 kg-m, 16.5 lb-ft)

CAUTION:

Tighten cover bolts little by little evenly in diagonal or-

der.

[4-speed & 5-speed Transmissions]

CLUTCH 7C-9

4) Slightly apply grease to input shaft (1), then joint transmission

assembly with engine.

“A”: Grease 99000-25010

“B”: Grease 99000-25210

NOTE:

Turn crankshaft with wrench from front while inserting

transmission input shaft to clutch disc until splines mesh.

7C-10 CLUTCH

CLUTCH RELEASE SYSTEM [FOR 5-SPEED

TRANSMISSION]

REMOVAL

1) Remove release arm by loosening its bolt.

2) Take out release bearing by turning release shaft.

3) Unhook return spring (1) using pliers.

4) Drive out No.2 bush using special tool and hammer.

Release shaft seal will also be pushed out.

Special Tool

(A): 09922-46010

5) Remove release shaft (2) and return spring (1).

6) Install tap (M14  1.5)(1) to clutch release shaft No.1 bush.

7) Pull No.1 bush out by using special tools.

Special Tool

(B): 09923-46030

(C): 09930-30102

CLUTCH 7C-11

INSPECTION

Clutch release bearing

Check clutch release bearing (1) for smooth rotation.

If abnormality is found, replace it.

CAUTION:

Do not wash release bearing. Washing may cause grease

leakage and consequential bearing damage.

Clutch release shaft

Check clutch release shaft (1) and its pin for deflection or damage.

If abnormality is found, replace it.

INSTALLATION

1) Drive in a new clutch release shaft No.1 bush (1) using special

tools and then apply grease to bush inside.

Special Tool

(A): 09943-77910

(B): 09923-46030

“A”: Grease 99000-25010

2) Install release shaft with return spring applied to it.

3) Apply grease to clutch release shaft No.2 bush (1) inside and

press-fit it using the same special tool as in removal.

Grease 99000-25010

Special Tool

(C): 09922-46010

4) Apply grease to shaft oil seal (1) and then install it till its upper

end flush with end face of transmission case using special tool.

“A”: Grease 99000-25010

Special Tool

(D): 09925-98221

7C-12 CLUTCH

5) Caulk seal (1) at A using caulking tool and hammer.

A: Caulking

6) Hook return spring (1).

7) Apply grease to release bearing (2) inside and release shaft arm

(3), then set bearing.

“A”: Grease 99000-25010

8) Apply small amount of grease to input shaft spline (4) and front

end as well.

“B”: Grease 99000-25210

9) Set release arm (1) to release shaft aligning their punching

marks (2) and tighten nut (3).

Tightening Torque

(a): 13 N·m (1.3 kg-m, 9.5 lb-ft)

CLUTCH 7C-13

7C-14 CLUTCH

REQUIRED SERVICE MATERIALS

MATERIAL

RECOMMENDED

SUZUKI PRODUCT

USE

SUZUKI SUPER GREASE A

D Clutch cable hook and joint pin

D Release shaft bushes and seal

Lithium grease

(99000-25010)

D Release

shaft

bushes

and

seal

D Release shaft arm.

SUZUKI SUPER GREASE I

(99000-25210)

Input shaft spline front end.

SPECIAL TOOLS

09917-58010

(For 5-speed M/T)

09921-20200

(For 4-speed M/T)

Bearing remover

09922-46010

Bush remover

09923-36330

Clutch center guide

09923-46030

Joint pipe

09924-17810

Flywheel holder

09925-98210

(For 5-speed M/T)

09943-88210

(For 4-speed M/T)

Input shaft bearing

installer

09925-98221

Bearing installer

09930-30102

Sliding shaft

09943-77910

Front suspension lower

arm bush remover

Clutch for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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