Air SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

MANUAL TRANSMISSION 7A-1
6F1
6F2
6G
6H
6K
7A1
7B1
7C1
7A
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7A
MANUAL TRANSMISSION
CONTENTS

GENERAL DESCRIPTION .............................. 7A-2
CONSTRUCTION AND SERVICING ........... 7A-2
TRANSMISSION FOR 2WD MODEL....... 7A-3
TRANSMISSION FOR 4WD MODEL....... 7A-4
DIAGNOSIS ..................................................... 7A-5
ON-VEHICLE SERVICE .................................. 7A-5
OIL CHANGE ............................................... 7A-6
DIFFERENTIAL SIDE OIL SEAL ................. 7A-6
GEAR SHIFT CONTROL LEVER AND
CABLE ......................................................... 7A-8
VEHICLE SPEED SENSOR (VSS) ............ 7A-10
UNIT REPAIR OVERHAUL ........................... 7A-11
TRANSMISSION UNIT............................... 7A-11
TRASMISSION CASE ................................ 7A-12
INPUT & COUNTER SHAFT...................... 7A-13
GEAR SHIFTER & DIFFERENTIAL ........... 7A-14
TRANSMISSION UNIT............................... 7A-16
UNIT DISASSEMBLY ................................ 7A-17
FIFTH GEARS........................................ 7A-17GEAR SHIFTER, INPUT SHAFT AND
COUNTER SHAFT................................. 7A-19
RIGHT CASE ......................................... 7A-20
SUB ASSEMBLY SERVICE ...................... 7A-21
RIGHT CASE ......................................... 7A-21
LEFT CASE............................................ 7A-21
INPUT SHAFT ASSEMBLY ................... 7A-22
COUNTER SHAFT ASSEMBLY ............ 7A-25
GEAR SHIFTER..................................... 7A-29
DIFFERENTIAL ASSEMBLY ................. 7A-30
UNIT ASSEMBLY ...................................... 7A-33
DIFFERENTIAL TO LEFT CASE ........... 7A-33
FIFTH GEARS ....................................... 7A-35
GEAR SHIFT AND SELECT SHAFT
ASSEMBLY ............................................ 7A-38
TIGHTENING TORQUE SPECIFICATION.... 7A-39
REQUIRED SERVICE MATERIAL................ 7A-40
SPECIAL TOOL ............................................ 7A-40

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

7A-2 MANUAL TRANSMISSION
GENERAL DESCRIPTION
CONSTRUCTION AND SERVICING
The transmission provides five forward speeds and one reverse speed by means of three synchronizers and
three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and
reverse uses a sliding idler gear arrangement.
The low speed synchronizer is mounted on counter shaft and engaged with counter shaft first gear or second
gear, while the high speed synchronizer is done on input shaft and engaged with input shaft third gear or fourth
gear.
The fifth speed synchronizer on input shaft is engaged with input shaft fifth gear mounted on the input shaft.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance
of shifting to 2nd gear.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
4WD model is equipped with transfer assembly on transmission being mated to right side of differential output in
transmission.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transmission case
which is made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque
wrench. It is also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reas-
sembling.
Further, care must be taken to adjust preload of counter shaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

MANUAL TRANSMISSION 7A-11
UNIT REPAIR OVERHAUL
TRANSMISSION UNIT
1. Engine 10. VSS connector 19. Engine rear mounting
2. Transmission 11. Transmission to engine bolts 20. Engine rear mounting No.2 bracket bolts
3. Engine rear mounting No.1 bracket 12. Engine left mounting bracket bolts 21. Transmission to engine rear mounting No.2 bracket bolt
4. Engine rear mounting No.2 bracket 13. Starting motor 22. Transmission to engine bolts
5. Engine left mounting 14. Starting motor bolt 23. Transmission to engine nut
6. Engine left mounting bracket 15. Engine rear mounting bracket stiffener 24. Ground cable
7. Shift & select control cables 16. Stiffener bolts 25. Clutch housing lower plate bolts
8. Clutch cable 17. Clutch housing lower plate 26. Starting motor nut
9. Backup lamp switch connector 18. Engine rear mounting bolt Tightening torque

MANUAL TRANSMISSION 7A-17
18) Remove engine left mounting (1) with bracket (2).
19) Remove other attached parts from transmission, if any.
20) Pull transmission out so as to disconnect input shaft from
clutch disc and then lower it.
REMOUNTING
Remount transmission in reverse order of dismounting procedure
noting the following.
 Refer to Section 7D for installing transfer (if equipped).
 Refer to the first figure of “UNIT REPAIR OVERHAUL” for
fastener specified torque.
 Push in drive shaft joints (right & left) fully so as to snap ring
of shaft engages with differential gear.
 Set each clamp for wiring securely.
 After connecting clutch cable, be sure to adjust its play prop-
erly.
Refer to Section 7C.
 Fill transmission with oil as specified.
 Connect battery and check function of engine, clutch and
transmission.
UNIT DISASSEMBLY
FIFTH GEARS
1) Remove side cover bolts and take off transmission side
cover.
CAUTION:
Care should be taken not to scratch oil seal lip with drive
shaft while raising transmission.
Do not hit drive shaft joint with hammer when installing it
into differential gear.
CAUTION:
Care should be taken not to distort side cover when it is
removed from left case.

MANUAL TRANSMISSION 7A-23
INSPECTION AND REASSEMBLY
1) Clean all components thoroughly, inspect them for any
abnormality and replace with new ones as necessary.
2) If synchronizer parts need to be repaired, check clearance
“a” between ring (2) and gear (1), each chamfered tooth of
gear, ring and sleeve, then determine parts replacement.
Clearance between synchronizer ring and gear
Standard “a” : 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit “a” : 0.5 mm (0.019 in.)
3) To ensure lubrication, air blow oil holes (1) and make sure
that they are free from any obstruction.
4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3
keys (2) in it and then set springs (1) as shown in figure.
Synchronizer key installation position
: A = B
5) Drive in right bearing (1) to input shaft (2) by using special
tool and hammer.
Special tool
(A) : 09913-80112
NOTE:
 No specific direction is assigned to each key but it is
assigned as sleeve & hub assembly.
 Size of high speed synchronizer sleeve, hub, keys and
springs is between those of low speed and 5th speed
ones.
[A] : 3rd gear side
C : Long flange
D : Key way
E : Projecting end

7A-26 MANUAL TRANSMISSION
8) Remove right bearing cone (2) by using puller (3), metal stick
(1) and press.
INSPECTION AND REASSEMBLY
1) Clean all components thoroughly, inspect them for any
abnormality and replace with new ones as necessary.
2) If synchronizer parts need to be repaired, check clearance
“a” between ring (2) and gear (1), each chamfered tooth of
gear, ring and sleeve, then determine parts replacement.
Clearance between synchronizer ring and gear
Standard “a” : 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit “a” : 0.5 mm (0.019 in.)
3) Put the synchronizer outer ring (1), inner ring (3) and the
cone (2) together and then measure the step difference
between the outer ring and the inner ring. And also check
each chamfered tooth of gear and synchronizer ring and
replace with new one, if necessary. Also, check gear tooth.
Difference between synchronizer outer ring and inner ring
Standard “b” : 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit “b” : 0.5 mm (0.019 in.)
4) To ensure lubrication, air blow oil holes (1) and make sure
that they are free from any obstruction.

AUTOMATIC TRANSMISSION (4 A/T) 7B-1
6F1
6F2
6G
6H
6K
7A
7A1
7C1
7D
7B
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7B
AUTOMATIC TRANSMISSION (4 A/T)
CONTENTS
GENERAL DESCRIPTION ...............................7B-3
ELECTRONIC SHIFT CONTROL SYSTEM . 7B-6
TRANSMISSION CONTROL MODULE
(TCM) ........................................................ 7B-7
FAIL SAFE FUNCTION ............................. 7B-8
CHANGE MECHANISM .......................... 7B-10
AUTOMATIC GEAR SHIFT DIAGRAM ... 7B-11
DIAGNOSIS ....................................................7B-13
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE ...................... 7B-13
TROUBLE DIAGNOSIS TABLE .................. 7B-18
STALL TEST ........................................... 7B-20
TIME LAG TEST ..................................... 7B-21
LINE PRESSURE TEST ......................... 7B-22
ENGINE BRAKE TEST ........................... 7B-23
“P” RANGE TEST.................................... 7B-23
ELECTRONIC CONTROL SYSTEM
DIAGNOSIS ................................................ 7B-24
PRECAUTIONS IN DIAGNOSING
TROUBLES ............................................. 7B-24
DTC CHECK ........................................... 7B-25
DTC CLEARANCE .................................. 7B-27
DTC TABLE............................................. 7B-28
TCM POWER AND GROUND CIRCUIT
CHECK .................................................... 7B-30
DTC P0715 (DTC NO.14) INPUT/
TURBINE SPEED SENSOR CIRCUIT
MALFUNCTION ...................................... 7B-31
DTC P0730 (DTC NO. 18) INCORRECT
GEAR RATIO .......................................... 7B-33
DTC P0753 (DTC NO.21/22) SHIFT
SOLENOID-A (NO.1) ELECTRICAL ....... 7B-35DTC P0758 (DTC NO.23/24) SHIFT
SOLENOID-B (NO.2) ELECTRICAL ....... 7B-35
DTC P0743 (DTC NO.25/26) TCC
(LOCK-UP CLUTCH) SYSTEM
ELECTRICAL .......................................... 7B-35
DTC P0741 (DTC NO.29) TCC
(LOCK-UP) SOLENOID
PERFORMANCE OR STUCK OFF ........ 7B-37
DTC P0720 (DTC NO. 31) OUTPUT
SHAFT SPEED SENSOR CIRCUIT
MALFUNCTION ...................................... 7B-38
DTC P1700 (DTC NO.32/33)
THROTTLE POSITION SIGNAL INPUT
MALFUNCTION ...................................... 7B-41
DTC P0705 (DTC NO.34)
TRANSMISSION RANGE SENSOR
(SWITCH) CIRCUIT MALFUNCTION ..... 7B-43
DTC P0725 (DTC NO.35) ENGINE
SPEED INPUT CIRCUIT
MALFUNCTION ...................................... 7B-45
DTC P0710 (DTC No.36/38)
TRANSMISSION TEMPERATURE
SENSOR CIRCUIT MALFUNCTION ...... 7B-47
DTC P0763 (DTC NO.43) SHIFT
SOLENOID-C (NO.3) ELECTRICAL ....... 7B-49
DTC P0768 (DTC NO.45) SHIFT
SOLENOID-B (NO.4) ELECTRICAL ....... 7B-49
DTC P0773 (DTC NO.48) SHIFT
SOLENOID-E (NO.5) ELECTRICAL ....... 7B-49
DTC P1709 (DTC NO.51) ENGINE
COOLANT TEMPERATURE/BAROMETRIC
PRESSURE SIGNAL CIRCUIT............... 7B-51 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

7B-2 AUTOMATIC TRANSMISSION (4 A/T)
DTC P0702/P1702 (DTC No.52)
TRANSMISSION CONTROL SYSTEM
ELECTRICAL OR INTERNAL
MALFUNCTION OF TCM ....................... 7B-52
INSPECTION OF TCM AND ITS
CIRCUITS ............................................... 7B-53
ON-VEHICLE SERVICE ................................. 7B-55
MAINTENANCE SERVICE ......................... 7B-55
FLUID LEVEL AT NORMAL OPERATING
TEMPERATURE ..................................... 7B-55
FLUID LEVEL AT ROOM
TEMPERATURE ..................................... 7B-56
FLUID CHANGE ..................................... 7B-56
SELECTOR LEVER .................................... 7B-57
TRANSMISSION RANGE SENSOR
(SHIFT SWITCH) ........................................ 7B-58
SELECTOR CABLE .................................... 7B-60
OUTPUT SHAFT SPEED SENSOR
(A/T VSS) .................................................... 7B-62
INPUT SHAFT SPEED SENSOR ............... 7B-63
VEHICLE SPEED SENSOR (VSS)............. 7B-63
THROTTLE POSITION SENSOR............... 7B-63
ENGINE COOLANT TEMP. (ECT)
SENSOR ..................................................... 7B-64
DROPPING RESISTOR ............................. 7B-64
O/D OFF SWITCH ...................................... 7B-65
SHIFT SOLENOID VALVES AND
TRANSMISSION TEMPERATURE
SENSOR ..................................................... 7B-65
SHIFT SOLENOID VALVES ................... 7B-66
TRANSMISSION TEMPERATURE
SENSOR ................................................. 7B-66
DIFFERENTIAL SIDE OIL SEAL ................ 7B-68TRANSMISSION CONTROL MODULE
(TCM).......................................................... 7B-69
LEARNING CONTROL INITIALIZATION 7B-70
BRAKE INTERLOCK SYSTEM
(IF EQUIPPED)........................................... 7B-70
KEY INTERLOCK CABLE
(IF EQUIPPED)........................................... 7B-72
TRANSMISSION UNIT REPAIR
OVERHAUL ................................................... 7B-75
DISMOUNTING .......................................... 7B-76
REMOUNTING ........................................... 7B-77
UNIT DISASSEMBLY ................................. 7B-78
DISASSEMBLY/ASSEMBLY OF
SUBASSEMBLY ......................................... 7B-88
OIL PUMP ............................................... 7B-88
FRONT CLUTCH (C2 CLUTCH) ............ 7B-91
REAR CLUTCH (C1 CLUTCH) ............... 7B-95
DIRECT CLUTCH (C0 CLUTCH) ......... 7B-100
PLANETARY SET................................. 7B-104
VALVE BODY ....................................... 7B-106
DIFFERENTIAL ASSEMBLY ................ 7B-112
REAR COVER (O/D BRAKE PISTON
ASSEMBLY) ......................................... 7B-115
PLANETARY SUN GEAR NO.1
ASSEMBLY .......................................... 7B-115
TORQUE CONVERTER HOUSING ..... 7B-116
TRANSMISSION CASE ........................ 7B-117
UNIT ASSEMBLY ..................................... 7B-118
TIGHTENING TORQUE SPECIFICATION .. 7B-136
SPECIAL TOOL ........................................... 7B-137
REQUIRED SERVICE MATERIAL .............. 7B-139

AUTOMATIC TRANSMISSION (4 A/T) 7B-13
DIAGNOSIS
This vehicle is equipped with an electronic transmission control system, which controls the automatic shift up
and shift down timing, etc. suitably to vehicle driving conditions.
When diagnosing a trouble in the transmission including this system, follow “AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE” given below to obtain correct result smoothly.
AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE
NOTE:
For the details of each step, refer to the following pages.
Step Action Yes No
1 Customer Complaint Analysis
1) Perform customer complaint analysis refer-
ring to the following page.
Was customer complaint analysis performed
according to instruction on the following page?Go to Step 2. Perform customer com-
plaint analysis.
2 Diagnostic Trouble Code (DTC) Check, Record
and Clearance
1) Check for DTC referring to the following
page.
Is there any DTC(s)?1) Print DTC or write it
down and clear it by
referring to “DTC
CLEARANCE” in this
section.
2) Go to Step 3.Go to Step 4.
3 Visual Inspection
1) Perform visual inspection referring to the fol-
lowing page.
Is there any faulty condition?1) Repair or replace mal-
function part.
2) Go to Step 11.Go to Step 5.
4 Visual Inspection
1) Perform visual inspection referring to the fol-
lowing page.
Is there any faulty condition?Go to Step 8.
5 Trouble Symptom Confirmation
1) Confirm trouble symptom referring to the fol-
lowing page.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6 Rechecking and Record of DTC.
1) Recheck for DTC referring to “DTC CHECK”
in this section.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7 Rechecking and Record of DTC.
1) Recheck for DTC referring to “DTC CHECK”
in this section.
Is there any DTC(s)?Go to Step 9. Go to Step 10.

7B-14 AUTOMATIC TRANSMISSION (4 A/T)
8 Automatic Transmission Basic Check and Trou-
ble Diagnosis Table
1) Check and repair according to “A/T BASIC
CHECK” and “TROUBLE DIAGNOSIS
TABLE” in this section.
Are check and repair complete?Go to Step 11. 1) Check and repair
malfunction part(s).
2) Go to Step 11.
9 Troubleshooting for DTC
1) Check and repair according to applicable
DTC Diagnostic Flow Table.
Are check and repair complete?
10 Check for Intermittent Problems
1) Check for intermittent problems referring to
the following page.
Is there any faulty condition?1) Repair or replace mal-
function part(s).
2) Go to Step 11.Go to Step 11.
11 Final Confirmation Test
1) Clear DTC if any.
2) Perform final confirmation test referring to
the following page.
Is there any problem symptom, DTC or abnor-
mal condition?Go to Step 6. End. Step Action Yes No