LuK clutch clinic – Suzuki Grand Vitara 1.6 petrol

In this article the LuK technical team takes a closer look at the Suzuki Grand Vitara which has covered close to 130,000 miles with quite harsh use through its life. Because of this it is important that particular attention is made to the whole transmission system for possible wear.

The Suzuki in question is the 1.6 16v petrol engine with the G16B engine code.

The vehicle is the original 4×4 with mechanical four-wheel engagement. Engine and transmission installed longitudinal with the transfer box installed directly onto the gearbox. The clutch change is quite straight forward with the only intervention under the bonnet to disconnect the battery terminal.

A two post ramp a couple of transmission jacks and a special alignment tool are required for the repair and a good attitude too health and safety due to the weight of the transmission is a must!!

Once the battery terminal has been disconnected the next stage is to disconnect the gear shift levers from the gearbox which takes place from inside the vehicle. This is done before the vehicle is lifted. First remove the handbrake console by removing the two bolts on the rear side, then remove the front section of the console held in place by two further bolts on the side and remove the clips on the side of the console between the seats (fig1).
Fig. 1


Access is now permitted for the 12mm bolts that retain the metal frame onto the main gear lever (fig2), this metal frame is to be removed to expose the gear selector. At that point the two side bolts should be removed (fig3) and the selector disconnected completely. The same procedure is followed for the four-wheel drive lever.

Fig. 3

The vehicle can now safely be lifted to move to the next stage of disconnecting the reverse gear plug, four-wheel drive selector sensor, the wiring harness that passes over the gearbox and finally the earth cable and stow all safely and securely. Remove the external slave cylinder held in place by two 12mm bolts (fig4) and stow securely and finally remove two bolts from the starter motor.

fig4Fig. 4

fig5Fig. 5

Mark the position of the propshaft before removing it as we do not want a balance issue afterwards and disconnect from the gearbox splines taking extra care not to damage the oil seal (fig5), the front section of the propshaft should remain fixed to the gearbox to avoid transmission oil leaks. Next support the gearbox with the transmission jacks and remove the cross member support for the gearbox. Loosen the anti roll bar allowing it to hang so this gives a clear space when removing the gearbox.

fig6Fig. 6

fig7Fig. 7

fig8Fig. 8

Now for the health and safety! with the gearbox supported by the transmission jacks and three sets of hands! Remove the four bell housing bolts and very carefully lower the gearbox to the ground.

Remove the old clutch cover and clutch plate. Check the bell housing for any debris and oil contamination and rectify before refitting the gearbox. The release bearing should always be changed during a clutch replacement, the release arm should be checked for smooth operation and for wear on the ball pivot. Apply a small amount of HMPG to the release fork (fig7&8) and install with the new release bearing (fig8). Check the flywheel for signs of heat stress such as hair line fractures or cracks, the surface of the flywheel should be checked to make sure it is within manufactures wear tolerance. If the surface of the flywheel is to be skimmed, make sure that the same amount is taken from the clutch bolting surface. Failure to check and rectify these areas may cause the clutch to operate incorrectly. Before fitting the new clutch disc make sure the input shaft is clean and free from any wear. In this case the spigot bearing was completely worn and noisy and was replaced. Smear a little high melting point grease on the input shaft splines then slide the new clutch plate up and down a couple of times, remove the plate and wipe any excess grease off.

Refitting the gearbox is the reversal of removal remembering to refill the gearbox oil to the correct level when the gearbox is refitted.

In addition to LuK clutch products, Schaeffler (UK) Ltd also supplies INA tensioner and FAG wheel bearings to the independent aftermarket. It has also recently introduced the Ruville engine, cooling and suspension components range and all brands are backed by technical support and repair installation tips through its industry leading internet site REPXPERT ( and a technical hotline; Tel: +44 (0)1432 264264.

Written by:

Published on: May 26, 2016

Filled Under: Clutch, Technical Articles

Web site:

Comments are closed.