automatic transmission SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5A-122 Automatic Transmission/Transaxle:
Oil Pump Assembly Disassembly and
Reassembly
S7RS0B5106035
Disassembly1) Remove O-ring from pump body.
2) Remove 8 oil pump subassembly bolts (1) and stator shaft assembly (2).
3) Remove oil seal (1) using special tool. Special tool
(A): 09913–50121
Reassembly 1) Install new oil pump body oil seal (1). Use special tool and hammer to install it, and then
apply grease to its lip portion.
Special tool
(A): 09913–85210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C) 2) Install driven gear and drive gear to oil pump body
after applying A/T fluid.
3) Install stator shaft assembly to oil pump body and tighten 8 pump subassembly bolts (1) to
specification.
Tightening torque
Oil pump subassembly bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
4) After applying A/T fluid to new O-ring, install it to oil pump body.
5) Check drive gear for smooth rotation by using torque converter (1).
Oil Pump Assembly InspectionS7RS0B5106036
1) Check body clearance of driven gear (1).Push driven gear to one side of oil pump body (2).
Using a feeler gauge, m easure clearance between
driven gear and body. If clearance exceeds its
standard value, replace oil pump assembly.
Clearance between oil pump driven gear and oil
pump body
Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.)
2. Oil pump body
2. Oil pump body
2 1
I4RS0A510041-01
I2RH0B510150-01
I2RH0B510151-01
1, (a)
I4RS0A510042-01
1
I4RS0A510043-01
I2RH0B510154-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-123
2) Check tip clearance of both drive and driven gears.Using a feeler gauge, m easure clearance between
drive and driven gear tips. If clearance exceeds its
standard value, replace oil pump assembly.
Tip clearance between oil pump drive gear and
oil pump driven gear
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
3) Check side clearance of both gears. Using a straightedge (1) and a feeler gauge (2),
measure side clearance between gears and pump
body.
If clearance exceeds its standard value, replace oil
pump assembly.
Side clearance between gears and oil pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.0019 in.)
4) Using special tool, measure stator shaft bush (1) bore.
If measured stator shaft bush bore is out of
specifications, replace oil pump assembly with new
one.
Special tool
(A): 09900–20605
Stator shaft bush bore
Standard: 18.424 – 18.450 mm (0.7254 – 0.7264
in.) 5) Install direct clutch asse
mbly (1) to stator shaft
assembly (2), then ensure that direct clutch
assembly turns smoothly.
If unsmooth rotation or noise are found in oil pump
assembly, replace oil pump assembly with new one.
This check should also be done to input shaft
assembly and replace input shaft assembly if
necessary.
6) Using special tool, measure oil pump body bush bore.
If measured oil pump body bush (1) bore is out of
specifications, replace o il pump assembly with new
one. Torque converter also needs to be checked.
Replace torque converter, if necessary.
Special tool
(A): 09900–20605
Oil pump body bush bore
Standard: 38.113 – 38.138 mm (1.5005 – 1.5015
in.)
I2RH0B510155-01
I2RH0B510156-01
I2RH0B510157-01
I2RH0B510158-01
I2RH0B510159-01

Downloaded from www.Manualslib.com manuals search engine 5A-124 Automatic Transmission/Transaxle:
Direct Clutch Assembly ComponentsS7RS0B5106037
Direct Clutch Assembly Preliminary CheckS7RS0B5106038
Install direct clutch assembly (1) to oil pump assembly
(2) blow in air (400 – 800 kPa, 4 – 8 kg/cm2, 57 – 113
psi) through oil hole (3) of oil pump assembly with
special tool attached on uppe r surface of direct clutch
piston, and measure piston stroke of direct clutch.
If piston stroke exceeds sp ecified value, disassemble,
inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
I2RH0B510160-01
1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate
2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring
3. Input shaft subassembly 8. Shaft snap ring : Apply automatic transaxle fluid.
4. Inner O-ring 9. Direct clutch separator plate : Do not reuse.
5. Direct clutch piston 10. Direct clutch disc
I2RH0B510161-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-125
Direct Clutch Assembly Disassembly and
Reassembly
S7RS0B5106039
Disassembly1) Remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates.
2) Using special tool and hydraulic press, remove shaft snap ring (1).
Special tool
(A): 09926–98310
CAUTION!
Do not press direct clutch return spring
subassembly in over 0.7 mm (0.027 in.).
Excessive compression may cause damage
to direct clutch return spring subassembly
and/or piston.

3) Remove direct clutch re turn spring assembly (2).
4) Using a finger to block oil hole (1), apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2, 57 –
113 psi) to opposite hole, which will assist in removal
of the clutch piston. 5) Remove outer O-ring (1).
6) Remove inner O-ring (2).
7) Remove input shaft seal rings (1).
I2RH0B510162-01
I2RH0B510163-01
I2RH0B510164-01
2. Direct clutch piston
1. Input shaft subassembly
I2RH0B510165-01
I2RH0B510166-01
I2RH0B510167-01

Downloaded from www.Manualslib.com manuals search engine 5A-126 Automatic Transmission/Transaxle:
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal ring and O-ring. Apply A/T fluid before installation.
• Do not damage direct clutch return spring subassembly (1) and piston by pressing in direct
clutch return spring subassembly passing through its
original installing position over 0.7 mm (0.027 in.).
Special tool
(A): 09926–98310
• Apply A/T fluid to direct cl utch separator plates (4),
discs (3) and retaining plate (2).
• Install direct clutch separator plates (4), discs (3), retaining plate (2) and snap ring (1) to input shaft
subassembly.
• Install plate snap ring so that its both ends would be positioned in correct locations as shown in figure. • After assembly, measure direct clutch piston stroke.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
When piston stroke is out of specification, select direct
clutch retaining plate with suitable thickness from
among the following table and replace it.
Available direct clutch retaining plate thickness
I2RH0B510168-01
I2RH0B510169-01
[A]: Correct [B]: Incorrect
ThicknessIdentification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
2.8 mm (0.110 in.) 4
1. Direct clutch assembly 3. Oil hole
2. Oil pump assembly
I2RH0B510170-01
I2RH0B510171-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-127
Direct Clutch Assembly InspectionS7RS0B5106040
Clutch Discs, Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated, discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Direct Clutch Return Spring Subassembly
Measure free length of direct clutch return spring.
Direct clutch return spring free length
“a”: 36.04 mm (1.419 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Direct Clutch Piston
Shake direct clutch piston lightly and check that check
ball (1) is not stuck.
Blow in low pressure air (Max. 100 kPa, 1 kg/cm
2, 15 psi)
to check ball to check that there is no leakage.
I2RH0B510172-01
I2RH0B510173-01
I2RH0B510174-01

Downloaded from www.Manualslib.com manuals search engine 5A-128 Automatic Transmission/Transaxle:
Forward and Reverse Clutch Assembly ComponentsS7RS0B5106041
I3RM0B510061-01
1. Forward clutch balancer8. Intermediate shaft seal ring15. Forward clutch retaining plate
2. Forward clutch return spring subassembly 9. Reverse clutch plate snap ring 16. Forward clutch disc
3. Forward clutch piston 10. Reverse clutch retaining plate 17. Forward clutch separator plate
4. Forward clutch piston O-ring 11. Reverse clutch separator plate 18. Balancer snap ring
5. Forward clutch drum 12. Reverse clutch disc : Apply automatic transaxle fluid.
6. Forward clutch drum O-ring 13. Reverse clutch cushion plate : Do not reuse.
7. Intermediate shaft subassembly 14. Forward clutch plate snap ring

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-129
Forward and Reverse Clutch Assembly
Preliminary Check
S7RS0B5106042
1) Install forward and reverse clutch assembly (1) to
transaxle rear cover (2), blow in compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) through oil
hole (4) of transaxle rear cover with the special tool
attached on the upper surf ace of reverse clutch
retaining plate (3), and measure reverse clutch
piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) through oil hole (1) of transaxle rear
cover with the special tool attached on the upper
surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Forward and Reverse Clutch Assembly
Disassembly and Reassembly
S7RS0B5106043
Disassembly
1) Remove reverse clutch plate snap ring (1) and take out reverse clutch retaini ng plate, discs, separator
plates and clutch cushion plate from intermediate
shaft subassembly.
2) Remove forward clutch plate snap ring (1) and take out forward clutch retaining plate, discs and
separator plates from forward clutch drum.
3) Remove balancer snap ring by using special tool and hydraulic press.
Special tool
(A): 09926–97610
CAUTION!
Do not press forward clutch return spring
subassembly in over 1.5 mm (0.059 in.).
Excessive compression may cause damage
to return spring subassembly and/or
balancer.

I2RH0B510176-01
I2RH0B510177-02
I2RH0B510178-01
I2RH0B510179-01

Downloaded from www.Manualslib.com manuals search engine 5A-130 Automatic Transmission/Transaxle:
4) Remove forward clutch balancer (1).
5) Remove forward clutch return spring subassembly
(1).
6) Install intermed iate shaft subassembly (1) to
transaxle rear cover (2). Apply compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) to oil hole (3)
of transaxle rear cover to remove forward clutch
piston (4). 7) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of transaxle rear cover to
remove forward clutch drum (2).
8) Remove forward clutch piston O-ring (1) from intermediate shaft subassembly (2).
9) Remove forward clutch drum O-ring (1) from forward clutch drum (2).
10) Remove intermediate shaft seal ring (1) from intermediate shaft subassembly (2).
2. Intermediate shaft subassembly
I2RH0B510180-01
I2RH0B510181-01
I2RH0B510182-01
I2RH0B510183-01
I2RH0B510184-01
I2RH0B510185-01
I2RH0B510186-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-131
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Before assembling, apply automatic transaxle fluid to component parts.
• Replace O-rings and seal ring with new ones.
• Do not damage forward clutch return spring subassembly and balancer (1) by pressing forward
clutch return spring subassembly passing through its
original installing position over 1.5 mm (0.059 in.).
Special tool
(A): 09926–97610
• Apply A/T fluid to forward clutch separator plates (1), discs (2) and retaining plate (3).
• Install forward clutch separator plates (1), discs (2) and retaining plate (3), then snap ring (4) to forward
clutch drum. • Install forward clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
I2RH0B510180-01
4
1
2 3
I5RW0C510062-01
[A]: Correct
[B]: Incorrect
I2RH0B510188-01