Suzuki Clutch Job! Part 1: Transmission Removal

I've been putting off this project way too long:
It's time to replace the tired CLUTCH in my own 2002 Suzuki XL-7 4x4!
Step 1: Remove the transmission...
Enjoy the struggle!
Ivan

[@HUBBABUBBADOOPYDOOP]

*When using a floor jack, I always use an appropriate sized* *square of 1/2" plywood between the lift and what's lifted.* *Both side's irregularities actually bite into the wood where* *they need to, and the platform also steadies your part.* *For everyone else- never cup a jack onto a thread Boss as a lifting point-* *it can snap off very easily.* *The clutch lever pivot ball is hardened; but, over time, they will wear into* *a can opener blade, and poke through. A new pivot is cheap & easy to change,* *so it won't ruin the new lever. "Extra" grease will not remedy this.* *You've done an excellent job here.*

[@glennph93]

My 2002 xl7 clutch fork punched all the way threw (198,000 miles) at the pivot. Mine was starting to have trouble disengaging/engaging in reverse for awhile. I ignored it ...til it bit me ..stranded. Nobody/transmission shops believed what I thought it was when it happen. So I did the job myself also considering I just paid some trans shop 18 months prior for a new clutch. It wasn't too bad except the y pipe. I chipped my front tooth getting it out(800 dentist bill- crap there went my savings). By the way the shop that did the work prior left out a 4 bolts(1 was a starter) and I believe the issue was the same thing then. From then on I feel better doing my own work. Current mileage 238,000

[@PineHollowAutoDiagnostics]

Nice! Glad to hear these tough little trucks can go the distance :)

[@clinte14]

TIP: If you have a punched out clutch fork, put a bolt though the hole of the punched out clutch fork, with the bolt head facing the slave cylinder nipple and a nut on the back. No tranny drop required :D I did this on my Isuzu Trooper and it got me by for several years before the clutch truly needed replacement and I put a new clutch fork in then. Isuzu Troopers have this problem too. I wonder if Isuzu's are same components or same OEM as Suzuki's.

[@jeremyanthony9300]

Excellent job so far Ivan. Can't wait to see part 2.

[@SmittySmithsonite]

My last "on the ground" engine swap was back in 2012. No creeper - just sliding in and out under the truck, outside in the driveway. Don't think I have it in me to do that again! HUGE respect from me, watching you do this tranny/transfer case removal. I could probably physically do it ... but probably not mentally, lol. My tolerance for stress drops by the month these days. Nice work, brother! The PHAD marathon continues. On to part 2! 👍🍻

[@patrickcrow5042]

I'm not sure it wouldn't be easier to pull the motor to complete that job. Good work, your videos are very helpful.

[@ronaldanderson9263]

Oh my, my. Best of blessing on this job!

[@rhkips]

Woohoo! A transmission is born! I can't help but notice it's facing kind of a funny direction for a compact Japanese SUV... ;)

[@lore927]

Great job Ivan, not easy doing that alone!

[@engineeringpunk]

I've done several Suzuki clutches over the years but never a XL7. I have done a few vitaras and I personally had an X-90 for several years. Good choice on the B/A clutch. I've used theirs on every one I've done and have always been pleased. Good choice on replacing the shift fork as well. Honestly I recommend replacing the master and slave cylinder at the same time. They're not expensive and they always eventually go bad and start leaking. I rebuilt the gearbox in my X-90 and to date it was the easiest manual transmission rebuild I've EVER done. No kidding once I had it out I had it fully rebuilt with new bearings, seals, and syncros in about 45 minutes.

[@PineHollowAutoDiagnostics]

Wow the forgotten Suzuki X-90! Hopefully I won't have to rebuild my transmission any time soon!

[@TheGarnerjustin73]

Those NTN bearings are very good quality, you'll find them on just about everything OEM Honda, even my Honda motorcycle uses NTN wheel and steering head bearings.

[@robertevans6481]

Oh those were the good old days....on to part 2!

[@johnaclark1]

Man, Ivan, we need to get you into a MaxJax. I bought one nearly two years ago and it was the best money I ever spent.

[@fieldsofomagh]

Nice bit of work. Takes a bit of doing. Manual a must !!

[@dc5723]

Same here Ivan. My girlfriend (wife) and I with some friends went offroading in our 1993 Toyota 4x4 p/u back in 1993 and the mud is still on some places.

[@somerandomguy3868]

This brings back some memories, did it once with regular floor jacks, rented a transmission jack a couple of times, after that used a lift, ah good times

[@throttlebottle5906]

lifts are great and all, but they do make a larger distance fall for dropped or falling items.

[@lylecheckeye6300]

I am glad those floor jacks hold good with all that yanking on the vehicle. :)

[@zx8401ztv]

That looks like a big chunky bell housing and gearbox :-) The trolley jacks just made that drop so much easyer, we don't always appreciate our tools but those jacks work so well :-D. Yep the fork/lever must be worn on the pivot, the thrust bearing must be very ill also. If the mud is bone dry, then spray your old engine oil everywhere, it's a good use for it :-D.

[@bluejayoutpost9170]

Been working on one of these for years now. Auto.trans. Mainly maintenance..Has 390,000 miles still going..at 303,000.replaced the fuel pump...The vehicle is a mail delivery rig and drives around 85 to 105 miles 6 days a week.. tks.for videos

[@PineHollowAutoDiagnostics]

Holy crap 390k miles?!? I'm afraid mine will rust away long before it gets that far haha

[@bluejayoutpost9170]

@@PineHollowAutoDiagnostics Here in Southeast Oregon no rust...we have dry climate..that's a good reason being here at least for mechanics...LOL..

[@thomastommy1192]

Awesome great video thanks for sharing.

[@tinkerwest]

You have some cojones to tackle that with two floor jacks. Kudos to you....👍

[@baxrok2.]

Nice job. Halfway there!

[@Malcarper]

That's a neat trick, using 2 jacks to lower the transmission.

[@xboxbml]

Good job!..part.2 please..thanks

[@zoidberg444]

You are a wizard with the floor jacks Ivan. When i do clutches i just prefer to man handle the gearboxes in and out but holy shit, you would never man handle that mess in your Suzuki out! It must weigh 200KG. As much as working on the floor might suck, i think working on the floor is better for your back, neck and shoulders. Working on a lift often means contorting your neck and arms into some odd positions.

[@themechanic6117]

Huge transmission! Brave taking on this job with no lift. I remember having to change my clutch on jack stands.i know it sucks lol

[@cjkersh]

No, these are relatively small and light as are most items on these great Lil Suzukis

[@axiom.ai.obviousbattletank7139]

I still love this zuki

[@kellyspeppers]

Was thinking you had a clutch fork problem when you said had to keep adjusting the peddle rod to get it to fully release.

[@LearningHowToWrench]

Didn’t mention the crank angle sensor on the bell housing removal - ouch that’s a bugger ! 2.0td 2005 4x4 Grand Vitara

[@85rx7se]

I agree, you should have a dust boot on the release fork. Don't forget to grease the pivot the fork rides on. Also you should put in the new pilot bearing & rear main seal while you can easily get to them. Check the flywheel for burns or scoring, as it may need to be resurfaced. And you should consider overhauling the slave and master cylinders for the clutch. Not costly and it probably needs it.

[@PineHollowAutoDiagnostics]

If it ain't broke I don't touch it haha

[@northernpatriot9078]

The .mud story LMAO oh Ivan at least you had the balls brother!!😎 Formerly chiefeaglebear

[@volvo09]

Sorta the story with my car, I think the clutch disc has a piece busted off... It was occasionally bouncing around and getting stuck (you could feel when it hit the clutch disk and grabbed suddenly out of no where) but it has stopped a while ago. I have been babying the clutch for a few k, but I need to do it eventually... It's been warning me! And my truck has the stock 270k mi clutch, I'd like to replace that one to get a nice pedal feel, but I don't want to deal with the rust.

[@jhsevs]

Hi. What engine was this? I am really thankful for this, makes it easier for me to see how to do things when swapping my own clutch in my 98 vitara td. Mine has the same transmission, but a slightly different bell housing.

[@josephwash109]

I was wondering what that clutch kit was for (I'd seen it in previous videos in the background). I figured I'd find out eventually.

[@williegillie5712]

I had to replace the clutch pressure plate and throw out bearing in my 98 Off road Ranger. Fun fun taking all the skid plates off, drive shafts, etc. and wouldn’t ya know Ford in its infinite wisdom put its slave cylinder inside the trans. On the input shaft. I had to do mine like yours. Had to put the truck in the air on jack stands. Saved the big bucks working on my own vehicles.

[@PineHollowAutoDiagnostics]

Nice!

[@Hellbillyhok]

a problem i found with my suzuki xl7 when i bought it recently was the actual 160mm long bolt holding clutch and brake levers was bent therefore it wasn't disengaging the clutch properly leading to it starting to slip, i fixed this by putting i high tensile bolt in, it aligned all the pedals and rods properly allowing full travel again but I'll still need to put a clutch in but i got the car real cheap amd i really like it for the room and its 110" wheelbase

[@45AMT]

Shouldn't there be a dust boot on the clutch fork to prevent dirt and wear on it?

[@mbeauvais2006]

Hi great work. I have the same vehicle but I believe my shifter that connects to gear box is issue because it only has a reverse problem. Anyway recommendations on what to change?

[@reecetaylor9518]

Thank you

[@2secondslater]

Heya Ivan, by adjusting the clutch pedal pushrod too far you can create problems, the master cylinder piston needs to be able to return back to it's disengaged position so the pressure relief port becomes uncovered and pressure between the master and slave is released. If you adjust the free play out of the pushrod, the system will hold pressure and gradually engage the release bearing and cause the clutch to slip. Make sure you have the specified pedal free play and pedal height with your new clutch mate.

[@PineHollowAutoDiagnostics]

Good tips. I just increased the travel while keeping the master cylinder rest point :)

[@northernpatriot9078]

You answered it I was just gonna ask why you got another fork but the stress given it that makes sense to ensure another 80k or so

[@Drtbiker88]

Replace the rear main seal while your in there, leaking or not

[@ChicagoDoItYourself]

Sorry didn't see your post... was on my phone (small screen)...totally agree too much work already to avoid it..it IS going to go bad soon..i deleted..my comment

[@jaredstrehlein5605]

True with any major car project, while your in there. Murphys law will also come to anyone.

[@Usmanthemecano]

Next time drive to Avoca and borrow Eric's lift for the weekend

[@josechevere5540]

I need help taking the bolts from the flywheel on a 2002 xl7 is automatic any one knows ?

[@wysetech2000]

I feel your pain rolling around on a creeper.

[@eddiereichel9354]

Did I miss the diagnosis video? Beck Arnley are great manufacturer and or reboxer. I bought a bosch purge valve the other day for a car lot car that actually had a Bosch part in it. Literally though that pilot and throwout bearing should be replaced on a clutch service. Personally id trust the bearings that came in a kit.

[@sumduma55]

That exhaust, unless it is aftermarket, is likely the same material. The problem is heat and vibration. Stainless steel will lose some of its properties when exposed to heat which is why weld seams will rust. At the Y and catalytic converter is going.to be the hottest part of the exhaust. You also have issues of it running lean and rich in different states of disrepair. (You have to know some is wrong in order to fix something that is wrong). But your motor and converter flanges will see the most vibration from the engine. This flexes and fatigues the metal a bit. Put it all together and you can see why one will wear faster that the rest of the exhaust.

[@jptrainor]

Is the clearance on that vehicle enough to save you if a jack stand fails?

[@PineHollowAutoDiagnostics]

Just about...

[@ChadGrays]

What camera do you use?

[@Garth2011]

"Heavy line work" ! Not so easy without a lift. We ought to get you a shop building made up where you park the cars with 12 foot header garage doors and a lift ! Seems like the clutch release fork is beyond it's use limits and the throw out bearing is dry of any grease, worn out. It also doesn't seem to travel over the center shaft sleeve very smooth so that need cleaned off really well as the new release bearing gets packed with grease in those grooves. Since it was driven in the mud bath, it would seem fair to replace the pilot bearing with a Japanese make too since the throw out bearing is dried out and rough, the pilot bearing likely is especially since it turns all the time. That mud bath is as you say, not good period.

[@ericpfiffner5615]

That's a rugged built SUV, no wonder you like it. I wasn't familiar so I Wiki'd it, sounds like the 2nd generation they turned it in to a soccer mom ride.

[@PineHollowAutoDiagnostics]

Yup 2nd gen XL-7 wasn't made to go off-road at all haha

[@ericpfiffner5615]

Once GM got involved, the party was over! Ha ha

[@robertoruiz7069]

Ivan ,i was wondering about the Trans clutch lever boot and lower trans case round plug,also the two air vents on top of the trans case....It appears that mud can make it's way to the clutch by the simple fact it's not a totally sealed unit.i would think off roading you would want to stop any mud from ingress to the clutch plate etc. am i wrong? thanks

[@bryanlatimer-davies1222]

I agree, my land rover bell housing was totally sealed except for a drain plug in the tool kit that you fitted for deep wading same deal with the timing belt case as well

[@bluejayoutpost9170]

I use 2 studs kitty.corner..on engine cut a slot in them with a 3" cutoff wheel and bevel on grinder..makes install a breeze..Just take screwdriver to remove...

[@jackwood8307]

Guy I worked with was doing this in his workshop which set away from his house and the trans dropped on his hand. No one checked on him for almost three hours and he nearly lost the hand. Be careful folks!

[@PineHollowAutoDiagnostics]

Holy crap must have been a heavy transmission!

[@jackwood8307]

Pine Hollow Auto Diagnostics/when it fell the pain caused him to faint and when he came to the pain every time he moved would make him sick. He laid there and screamed for help till he lost his voice. His wide came in finally to check on him and called 911!😳

[@serafinsilva1055]

Isn't there suppose to be a boot on the fork?

[@thesteaktc]

This was scary to watch, you balancing the transmission on two jacks. Was constantly scared it was going to fall off.

[@renof2505]

How did you get the upper bell housing bolts out? I am working on an 02 with an automatic and I can't even see the passenger side top bolt.

[@PineHollowAutoDiagnostics]

I used some really long 1/2" extensions...like 6 feet long plus a breaker bar. Tilt the bottom of the trans down and you will be able to see them.

[@renof2505]

@@PineHollowAutoDiagnostics Great! Thanks for answering!

[@nathanrspain]

Did the camera break??

[@brucepierce6124]

Need to check the crank sensor while the trans is out.

[@zoneb609]

Pressure wash everything!

[@martyjr540]

Do you plan on doing anything with the Flywheel surface? I know on Class 8 Trucks when doing a clutch job it is always good habit to re grind the face..

[@PineHollowAutoDiagnostics]

Nah it's flat and smooth :)

[@williegillie5712]

Pine Hollow Auto Diagnostics I like to break the glaze off with and orbital sander. Is it necessary? I think in a smaller vehicle it’ll work either way.

[@throttlebottle5906]

so, grease the fork lightly with every oil change? sounds like a winner to me ;)

[@marlinknable3543]

Did you ever use (Free All) rust deep penetrating oil? I found it watching another KZbinrs that was working on a very rusty VW van she was getting very rusted bolts loose with it so I went and bought a can! I am amazed!

[@PineHollowAutoDiagnostics]

I will look it up!

[@gonzgarr1592]

Ivan you should invest on a mid lift that can lift up to 6000 lbs and rise to about 54 inches they are not that much and would make your work on cars much easier

[@klc317]

Hmmm...guess I would have never considered a Suzuki SUV back in that cars vintage but it looks surprisingly decent in build quality. Especially from being in salty winters.

[@PineHollowAutoDiagnostics]

It's holding up OK. Gotta spray some fluid film before winter!

[@Blazer02LS]

They are a tough little truck. The earlier ones like the Samurai and the "Geo" Tracker (aka Suzuki Sidekick) are highly sought after out west as trail vehicles. They are off road beasts when put together right. Smaller and lighter than anything but the early Jeep CJs.

[@fredflintstone8048]

I enjoyed the mud story.. Doing dumb things is all part of growing up.

[@PineHollowAutoDiagnostics]

At least I know that my truck can go through a 4-foot deep puddle haha

[@michaelweatherhead9470]

My 97 civic hx went 499k before I changed the clutch,pressure plate and bearings all Honda parts from majestic Honda RI discount parts.

[@SGDeGalvez]

22:44 i nearly shat myself. I thought it fell on you.

[@ColePEET]

Heya buddy, any tips on how to bleed the soft clutch pedal into normal operation? I am doing something wrong and just can't get it to not be soft anymore.

[@PineHollowAutoDiagnostics]

Is it moving the slave cylinder?

[@ColePEET]

@@PineHollowAutoDiagnostics yessir, did this same job but didn't use nice new parts like you did, used janky old parts. If the slave is moving does that mean it's primed and the problem is a shitty rusty throwout bearing and a nasty broken clutch fork not moving properly? I ordered a clutch kit and a throw out bearing but hoping its just something wrong with the prime.

[@PineHollowAutoDiagnostics]

@@ColePEET Sometimes new parts are necessary haha

[@dontderockmeriz4546]

Those are great cars. Had a 2002. Sold it at 107K 8 years ago. Still running strong. Only issue with 80% of those is the A/C compressors seize between 50-100K. Yours take a shit yet?

[@PecanPie1102]

Did you ever think of getting electric hydraulic scissor lift about 4 to 5 feet on door rails ?

[@PineHollowAutoDiagnostics]

No....need my floor space :)

[@throttlebottle5906]

on a hydraulic clutch setup, you pretty much never adjust anything, except for flushing the fluid and bleeding the air back out. if anything changes in the feel or travel, 99% chance the clutch/pressure plate/bearing or is having a mechanical failure. if it was a cylinder(master/slave) it would have bleed off and take off by itself with pedal pushed or not disengage fully and have a very soft throw.

[@wallacegardner5090]

The mud is mother nature protection service, and its free

[@ronwade5646]

Yes! My Afternoon off... Goofy sudden Slop means something changed.

[@user-zc7qb9dq6x]

Добрый день, Иван! Вы полны энергии - это великолепно! Здесь в России, многие ремонтируют автомобили сами, пользуясь смотровой ямой. Вам известно о смотровой яме? Если ваш дом построен на сухой почве, то это будет дешевое решение. Иван, скажите пожалуйста, какая модель двигателя на Вашей XL-7? Наверное, H27A? Смотрю с интересом! Денис.

[@PineHollowAutoDiagnostics]

Здорова, Денис! Ага, Н27А V6. Норм движок, только цепи иногда бренчат...

[@user-zc7qb9dq6x]

@@PineHollowAutoDiagnostics Спасибо за ответ, Иван! У меня есть такой же автомобиль, и проблема. В России, таких автомобилей мало. В моем городе, вообще нет. Можно нам поговорить, например по e-mail, или Skype? Заранее спасибо, Денис!

[@skiplazauski1497]

With 160K miles on the vehicle I suggest putting in a new slave cylinder and fluid line as well. As long as you're there maybe the master cylinder too.

[@PineHollowAutoDiagnostics]

Eh if they start leaking then we'll do that separately :)

[@GhettoWagon]

We want to see MORE MUD! Pressure wash that thing

[@throttlebottle5906]

just strap or tie the front driveshaft to the transmission itself, then no worries about a floppy part falling out or on to you lol

[@axiom.ai.obviousbattletank7139]

My clutch went out of nowhere (I'm a truck driver so i probably am not the best judge) The shop i contracted (Goodyear surprise) Keeps telling me " should be this afternoon" ..

[@petar443]

Can you make a brake master cylinder replacement video?

[@PineHollowAutoDiagnostics]

If I need to replace one, sure!

[@kevinbarry71]

Glad you can still get OEM parts. Suzuki pulled out of the United States so the dealers are all gone now.

[@PineHollowAutoDiagnostics]

I should stock up while there's time lol

[@147andreluiz]

Suzuki is alive and kicking all around the world. They can't be bothered with the States only. You still can get new parts for old cars.

[@kevinbarry71]

@@147andreluiz they are alive, selling cheap cars in Third World markets mostly. Being bothered? They left the US because they simply couldn't compete

[@147andreluiz]

@@kevinbarry71 Ok then =)

[@jeremyanthony9300]

Ivan , did you know that today was Eric o's 40th birthday. Honestly , i thought he was already 40.

[@dapend3915]

No new clutch slave cylinder ?

[@PineHollowAutoDiagnostics]

Why? Old one is working fine lol

[@dapend3915]

@@PineHollowAutoDiagnostics A while your there moment.

[@patrickcrow5042]

Seems almost like it'd be easier to change the clutch by removing the engine.

[@ericcorse]

Hot dog a wrenching video.

[@tmanda323]

Hi Ivan what kind of Russian are you when you dont drive Lada niva? hehehehehehe

[@khakiswag]

Millennials: why does it have 3 pedals?

[@GhettoWagon]

Extra brake to stop faster

[@BlindBatG34]

More like Americans.

[@alungibbon9146]

The manufacturer not the country of manufacture of components

[@alitopadamcanmuradmineski26]

Wasn't Doesn't aka Suzuki XL7

[@Coordinator61]

Never do these heavy gearbox jobs on the floor. It can break your back. Always on a ramp with proper gearbox jacks.

[@trippplefive]

surprised you can still find original suzuki parts in the US.

[@byrd203]

send it to the scrap yard those cars are money pits why do you think they quit selling to everyone

[@PineHollowAutoDiagnostics]

Really? Haven't done much to mine except for that timing chain tensioner. Much less fussy than a Subaru, and it can actually go off road!

[@65blablabla]

You should get a lift ,you make me nervous when you work on the floor with just jack stands....we wouldn't want you to get hurt..

[@PistonBikers]

My Favorite Güero KZbinr De Also Have A Chanel Named Pistón Bikers And Se Share Same Passion For Engines

[@donald1056]

You go thru those play mud holes - you'd better have a lot of money to pay for the repairs - bookoo $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ + labor

[@marty0715yt]

Time for a lift. Start whining to Momma for some money. Or a new garage!!

[@lar4305]

Haha yea my days of crawling under cars are over. No lift , no fix.

[@phillipjones3342]

OK I have been watching your videos frequently I need to say if you’re going to use visual aids in your explanation put some light on the subject you’ve been doing this a long time come on man

[@tcifusion4497]

OH MAN U NEED A LIFT.......SCARED OF THE TRAN HANGING OVER JACKS..........EURO STYLE....ON THE GROUND.....STILL DO THAT...HA HA HA....

[@bradanderson1627]

🤔kids stuff WTH

[@jamespn]

In hind sight wallowing around in a mud pit isn’t good for your 4wd truck.

[@animalcorvair]

keep the olds junk this ,,,

[@PineHollowAutoDiagnostics]

But I need 4x4 lol

[@animalcorvair]

@@PineHollowAutoDiagnostics i know just kidding

[@animalcorvair]

but you do need a rack