Unit SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5A-94 Automatic Transmission/Transaxle:
5) Turn ignition switch to LOCK position.
6) Remove parking brake cover and console box.
7) Detach cable end (1) from interlock cam (2) while
pressing claws (3) of interlock cam boss.
At this time, be careful no t to cause damage to its
claws.
Detach cable casing cap (4 ) from selector bracket
(5) while pressing check hook.
8) Remove interlock cable.
Installation 1) Lay interlock cable to its original cabling route.
2) Turn ignition switch to ACC position.
3) Insert cable casing cap (1) into key cylinder cover (2) securely. 4) Pull out lock button (1) of selector side cable end (2).
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1. Key interlock cable 4. Key cylinder cover7. Brake switch bracket
2. Clamp 5. Select lever assembly 8. Wiring harness
3. Steering lock assembly / Steering lock unit (Keyless start model) 6. EPS control module
9. Marking
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-97
Installation1) Apply A/T fluid to input shaft speed sensor O-ring.
2) Install input shaft speed se nsor (1) to A/T case and
tighten bolt to specified torque.
Tightening torque
Input shaft speed sensor bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
3) Connect input shaft speed sensor connector (2) to input shaft speed sensor (1).
4) Connect negative cable to battery.
Input Shaft Speed Sensor InspectionS7RS0B5106019
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Check resistance between input shaft speed sensor (1) terminals.
Input shaft speed sensor resistance
Standard: 560 – 680 Ω at 20 °C (68 °F)
Transmission Fluid Temperature Sensor
Removal and Installation
S7RS0B5106020
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) With engine is cool, remove drain plug and drain A/T fluid.
4) Install drain plug. Refer to “A/T Fluid Change”.
5) Remove A/T oil pan.
6) Remove oil stra iner assembly. 7) Remove valve body assembly referring to
“Automatic Transaxl e Unit Disassembly”.
CAUTION!
When pulling solenoid wire harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

8) Remove solenoid wire harness (1).
Installation
Reverse removal procedure to install solenoid wire
harness and valve body assembly noting the following
points.
• For details of valve body assembly and their connectors installation, refer to “Automatic Transaxle
Unit Assembly”.
• For details of A/T oil pa n installation, refer to
“Automatic Transaxle Unit Assembly”. Use new oil
pan gasket.
• Tighten valve body harness connector bolt to specified torque.
Tightening torque
Valve body harness connector bolt (a): 7.0 N·m (
0.7 kgf-m, 5.0 lb-ft)
• Pour A/T fluid and check fluid level according to procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-101
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Pressure Control
Solenoid) Removal and Installation
S7RS0B5106024
Removal1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
5) Remove A/T oil pan (1) and oil pan gasket (2).
6) Remove oil strain er assembly (3).
7) Remove transmission fluid temperature sensor (1) from sensor clamp.
8) Disconnect solenoid connectors (2). 9) Remove valve body assembly referring to
“Automatic Transaxl e Unit Disassembly”.
10) Remove pressure control solenoid valve and TCC pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC pressure control solenoid va lve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body asse mbly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “A utomatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valve InspectionS7RS0B5106025
CAUTION!
• Be very careful as dust etc. does enter when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-105
Automatic Transaxle Unit ComponentsS7RS0B5106030
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1. Drive plate4. Torque converter7. Transaxle and engine fastening nut
2. Drive plate bolt : Apply sealant 99000-31230 to thread. 5. Transaxle stiffener bolt
: Tightening torque
3. Drive plate to torque converter bolt 6. Transaxle and engine fastening bolt

Downloaded from www.Manualslib.com manuals search engine 5A-106 Automatic Transmission/Transaxle:
Automatic Transaxle Unit Dismounting and
Remounting
S7RS0B5106031
Dismounting1) Take down transaxle with engine. For its procedure, refer to “Engine Assembly Removal and Installation
in Section 1D”.
2) Remove transaxle housing lower plates (1).
3) Remove drive plate to torque converter bolts (1) engage flat head rod or the like (2) with drive plate
ring gear. 4) Remove starting motor.
5) Remove bolts and nut fastening engine and
transaxle, then detach transaxle from engine.WARNING!
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
the work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.

NOTE
When detaching transaxle from engine, move
it in parallel with cranks haft and use care so
as not to apply excessive force to drive plate
and torque converter.

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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-107
Remounting1) Make sure that torque converter is installed correctly to transaxle.
Refer to “Automatic Transaxle Unit Assembly”.
2) Attach transaxle to engine.
WARNING!
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
the work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.

Tightening torque
Transaxle and engine fastening bolt and nut
(a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
3) Tighten drive plate to torque converter bolts. Align bolt hole of drive plate and torque converter then
tighten bolts through torque converter housing lower
plate opening.
Lock drive plate (1) by engaging flat head rod or the
like (2) with drive plate gear.
Tightening torque
Drive plate to torque converter bolt (a): 25 N·m (
2.5 kgf-m, 18.0 lb-ft) 4) Tighten transaxle stiffener bolts to specified torque.
5) Install transaxle housing lower plates (1).
Tightening torque
Transaxle stiffener bolt (a): 55 N·m (5.5 kgf-m,
40 lb-ft)
6) Install starter motor. Tightening torque
Starter motor bolt and nut: 50 N·m (5.0 kgf-m,
36.5 lb-ft)
7) Remount engine with transaxle assembly to vehicle. Refer to “Engine Assembly Removal and Installation
in Section 1D” for its procedure.
3. Wrench 4. Engine oil pan
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(a)
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Downloaded from www.Manualslib.com manuals search engine 5A-110 Automatic Transmission/Transaxle:
Automatic Transaxle Unit DisassemblyS7RS0B5106033
CAUTION!
• Thoroughly clean transaxle exterior before overhauling it.
• Keep working table, tools and hands clean while overhauling.
• Use special care to handle aluminum parts so as not to damage them.
• Do not expose removed parts to dust. Keep them always clean.

1) Remove torque converter (1).
CAUTION!
Remove torque converte r as much straight
as possible. Leaning it may cause to damage
oil seal lip.

2) Remove engine mounting LH bracket (1).
3) Remove manual select lever (1). 4) Uncaulk lock washer (1),
then remove lock nut (2)
and lock washer.
5) Remove transmission range sensor (1).
6) Remove output shaft speed sensor (2) and input shaft speed sensor (1).
7) Remove harness bracket (3) and select cable clamp (4).
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-119
60) Remove snap ring while the 1st and reverse brake piston return springs are compressed using special
tool and hydraulic press.
CAUTION!
Do not press 1st and reverse brake return
spring subassembly in over 0.8 mm (0.031
in.).
Excessive compression may cause damage
to return spring subassembly, discs, plates
and/or piston.

Special tool
(A): 09926–97620
61) Remove 1st and reverse brake retaining plate, discs and separator plates.
62) Remove 1st and reverse brake return spring subassembly (1).
63) Turn over transaxle and uncaulk reduction drive gear nut (1). 64) Secure reduction drive gear (1) with parking lock
pawl, then remove reduction drive gear nut.
CAUTION!
• It is recommended that this operation should be carried out on rubber mat to
prevent damaging transaxle case.
• Never reuse removed nut.

65) Using special tools and hydraulic press, remove planetary ring gear subassembly (1).
CAUTION!
Do not reuse planetary ring gear
subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.

Special tool
(A): 09913–84510
(B): 09923–78210
66) Remove parking lock pawl shaft, then spring (2) and parking lock pawl (1).
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

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Downloaded from www.Manualslib.com manuals search engine 5A-150 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS7RS0B5106060
CAUTION!
• Automatic transaxle consists of highly precise parts. As even flaw in small part
may cause oil leakage or decrease in
function, check each part carefully before
installation.
• Clean all parts with compressed air. Never use wiping cloths or rags.
• Before assembling new clutch or brake discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before
assembly.
• Use Suzuki Super Grease “C” to retain parts in place.
• Be sure to install thrust bearings and races in correct direction and position.
• Make sure that snap ring ends are not aligned with one of cut outs and are
installed in groove correctly.
• Do not use adhesive cements on gaskets and similar parts.
• Be sure to torque each bolt and nut to specification.

1) Install new manual shift sh aft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.5 – 1.5 mm (0.02 – 0.06 in.) 2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl ro d (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using spring pin remover with 3.5 mm (0.14 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
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