Suzuki Aerio, Verona 2002-06

Driven Disc & Pressure Plate

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the transaxle.
  4.  
  5. Hold the flywheel stationary.
  6.  
  7. Matchmark the pressure plate and flywheel for installation reference.

    Click image to see an enlarged view

    Fig. Clutch component identification

  8.  
  9. Loosen the pressure plate attaching bolts 1 turn at a time (evenly) until the spring pressure is released.
  10.  
  11. Remove the clutch disc and pressure plate.
  12.  

To install:

  1. Clean the flywheel mating surfaces of all oil, grease and metal deposits. Inspect flywheel for cracks, heat checking or other defects and replace or resurface as necessary.
  2.  
  3. Check the wear on the facings of the clutch disc by measuring the depth of each rivet head depression. Replace clutch disc when rivet heads are 0.02 in. (0.5mm) below the surface of clutch surface.
  4.  
  5. Check the diaphragm spring and pressure plate for wear or damage. If the spring or plate is excessively worn, replace the pressure plate assembly.
  6.  
  7. Check the pilot bearing for smooth operation. If the bearing does not spin freely, replace it.
  8.  
  9. Position the clutch disc and pressure plate with the matchmarks aligned and install a clutch alignment tool.
  10.  
  11. Install the pressure plate bolts. Tighten the mounting bolts evenly and in a crisscross pattern to 17 ft. lbs. (23 Nm). Remove the alignment tool and the flywheel holding tool.
  12.  
  13. Lightly lubricate the transaxle input shaft splines, pilot bearing surface of the input shaft, and the release bearing with grease.
  14.  
  15. Install the transaxle.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the transaxle.
  4.  
  5. Hold the flywheel stationary.
  6.  
  7. Matchmark the pressure plate and flywheel for installation reference.

    Click image to see an enlarged view

    Fig. Clutch component identification

  8.  
  9. Loosen the pressure plate attaching bolts 1 turn at a time (evenly) until the spring pressure is released.
  10.  
  11. Remove the clutch disc and pressure plate.
  12.  

To install:

  1. Clean the flywheel mating surfaces of all oil, grease and metal deposits. Inspect flywheel for cracks, heat checking or other defects and replace or resurface as necessary.
  2.  
  3. Check the wear on the facings of the clutch disc by measuring the depth of each rivet head depression. Replace clutch disc when rivet heads are 0.02 in. (0.5mm) below the surface of clutch surface.
  4.  
  5. Check the diaphragm spring and pressure plate for wear or damage. If the spring or plate is excessively worn, replace the pressure plate assembly.
  6.  
  7. Check the pilot bearing for smooth operation. If the bearing does not spin freely, replace it.
  8.  
  9. Position the clutch disc and pressure plate with the matchmarks aligned and install a clutch alignment tool.
  10.  
  11. Install the pressure plate bolts. Tighten the mounting bolts evenly and in a crisscross pattern to 17 ft. lbs. (23 Nm). Remove the alignment tool and the flywheel holding tool.
  12.  
  13. Lightly lubricate the transaxle input shaft splines, pilot bearing surface of the input shaft, and the release bearing with grease.
  14.  
  15. Install the transaxle.
  16.  

 
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