Suzuki Carry won't go into 1st gear | DA63T Suzuki Carry clutch replacement

This Suzuki Carry kei truck wouldn't go into 1st gear, so I decided it needed a new clutch. This video shows you the clutch replacement process.

Before embarking on clutch replacement I checked that the problem couldn't be resolved by adjusting the clutch cable. Unfortunately for me, it couldn't!

I started by raising the truck up nice and high, so there was plenty of space for me and the transmission jack underneath. Next it was time to disconnect the battery, prop shafts, electrical connections and control cables. I removed the starter motor and then removed the gearbox.

With the clutch removed, there wasn't one obvious catastrophic failure, but the pressure plate, friction disc and release bearing were clearly all past their best.

Here is a link to the Luk clutch failure analysis guide I mentioned in the video:
https://www.partinfo.co.uk/files/LUK%...

I fitted a new Aisin 3 piece clutch kit (you can contact me here https://andrewsjapanesecars.com/ask-m... if you need parts for your Suzuki Carry) and then put it all back together.

I'm pleased to report the new clutch fixed the not shifting into 1st gear issue and transformed the driving experience!

Sections
0:00 Introduction
4:35 Disconnecting the battery
4:41 Draining the gearbox oil
6:09 Disconnecting front and rear prop shafts
9:01 Removing starter motor
9:48 Sensor cables
11:13 Shift control cables
15:07 Clutch cable
15:52 Removing the gearbox
18:29 Removing old clutch
19:51 Removing release bearing
21:03 Clutch failure analysis
23:39 Fitting new release bearing
26:37 Fitting new clutch
36:03 Clutch cable fitting and adjustment
36:41 New gear oil
37:11 Summary

#suzukicarry #clutch #keitruck

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