differential SUZUKI SWIFT 2000 1.G Transmission Service User Guide

7A-20 MANUAL TRANSMISSION
11) Tapping input shaft end with plastic hammer, push it out as
assembly from case a little, then take out input shaft assem-
bly (1), counter shaft assembly (2), high speed gear shift
shaft (3) and low speed gear shift shaft (4) all at once.
12) Remove counter shaft left bearing cup from left case.
13) Remove differential side left oil seal also from left case.
RIGHT CASE
1) Remove differential gear assembly (1) from right case (2).
2) Remove bolt and then pull out VSS (3).
3) If input shaft right bearing has been left in right case, pull it
out by using special tools.
Remove input shaft oil seal (1) by using special tools.
Special tool
(A) : 09930-30104
(B) : 09923-74510
4) Also pull out countershaft right bearing cup (2) by using spe-
cial tools.
Special tool
09941-64511
09923-30104

MANUAL TRANSMISSION 7A-21
SUB ASSEMBLY SERVICE
RIGHT CASE
1) Install input shaft oil seal (1) facing its spring side upward.
Use special tool and hammer for installation and apply
grease to oil seal lip.
“B” : Grease 99000-25010
Special tool
(A) : 09951-76010
2) Install countershaft right bearing cup (2) by using special
tools and hammer.
Special tool
(B) : 09924-74510
(C) : 09925-68210
LEFT CASE
1) If input oil gutter has been removed, install it with bolt to
which thread lock cement have been applied.
“A” : Thread lock cement 99000-32110
Tightening torque
Oil gutter bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
2) Install differential side left oil seal (1) facing its spring side
inward until it becomes flush with case surface by using spe-
cial tool with hammer, and then apply grease to its lip.
“B” : Grease 99000-25010
Special tool
(A) : 09913-75510
3) Install counter shaft left bearing cup into case bore by tap-
ping it with plastic hammer lightly. NOTE:
Before installation, wash each part and apply specified
gear oil to sliding faces of bearing and gear.

7A-30 MANUAL TRANSMISSION
2) Insert each gear shift shaft into case and check that it moves
smoothly. If it doesn’t, correct by using oilstone, reamer or
the like.
5th & Reverse Gear Shifter
1) Disassemble component parts by using special tool and
hammer.
Special tool
(A) : 09922-85811
2) Replace or correct parts as required and assemble shafts
making sure that component parts are in proper order as
shown in figure.
DIFFERENTIAL ASSEMBLY
DISASSEMBLY
1) Using special tools, remove right bearing (1) and sensor
rotor (2).
Special tool
(A) : 09913-60910
(B) : 09925-88210
2) Remove left bearing in the same manner.
3) Support differential case with soft jawed vise and remove
final gear bolts then take out final gear. NOTE:
 Distinguish reverse gear shift arm spring (Blue) (2)
from low speed locating spring (Yellow).
 Install 2 steel balls (3) in reverse gear shift arm (1) with-
out fail.
 Drive in spring pin for reverse shift arm facing slit A
toward front.
1. Reverse gear shift arm 6. 5th & reverse gear shift yoke
2. Reverse gear shift arm spring (Blue) 7. 5th & reverse gear shift guide shaft
3. Steel ball 8. 5th gear side
4. Spring pin A: Face pin slit toward 5thn gear side
5. 5th & reverse gear shift shaft

MANUAL TRANSMISSION 7A-31
4) Using special tool and hammer, drive out differential pinion
shaft pin and then disassemble component parts.
Special tool
(C) : 09922-85811
ADJUSTMENT AND REASSEMBLY
Judging from abnormality noted before disassembly and what is
found through visual check of component parts after disassembly,
prepare replacing parts and proceed to reassembly. Make sure
that all parts are clean.
1) Assemble differential gear and measure thrust play of differ-
ential gear as follows.
Differential gear thrust play
: 0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
 Hold differential assembly with soft jawed vise and apply
measuring tip of dial gauge to top surface of gear.
 Using 2 screwdrivers (1), move gear (2) up and down and
read movement of dial gauge pointer.
Special tool
(A) : 09900-20606
(B) : 09900-20701
Right side
 Using similar procedure to the above, set dial gauge tip to
gear (1) shoulder.
 Move gear up and down by hand and read dial gauge.
Special tool
(A) : 09900-20606
(B) : 09900-20701
2) If thrust play is out of specification, select suitable thrust
washer from among the following available size, install it and
check again that specified gear play is obtained.
Available thrust washer thickness
0.9, 0.95, 1.0, 1.05, 1.1, 1.15 and 1.2 mm
(0.035, 0.037, 0.039, 0.041, 0.043, 0.045, and 0.047 in.)
1. Differential case
2. Differential gear
3. Differential pinion shaft

7A-32 MANUAL TRANSMISSION
3) Drive in new differential pinion shaft pin (2) till the depth from
differential case (3) surface is about 1 mm (0.04 in.).
4) Press-fit new sensor rotor (1) with groove (4) side downward
as shown by using special tools and copper hammer.
Special tool
(A) : 09913-75510
(B) : 09940-54910
5) Press-fit left bearing by using special tools and copper ham-
mer.
6) Support differential assembly (1) as illustrated so as to left
bearing (2) is floating, and then press-fit right bearing (3) like
left bearing in Step 5).
Special tool
(C) : 09951-76010
(D) : 09951-16060
7) Hold differential assembly with soft jawed vise (3), install final
gear (2) as shown in figure and then tighten bolts (1) with
thread lock cement applied to specified torque.
“A” : Thread lock cement 99000-32110
Tightening torque
Final gear bolts (a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
NOTE:
Make sure to install final gear in correct installing direc-
tion.
CAUTION:
Use of any other bolts than specified ones is prohibited.
4. Groove

MANUAL TRANSMISSION 7A-33
UNIT ASSEMBLY
DIFFERENTIAL TO LEFT CASE
ASSEMBLY
1) Install differential assembly (1) into right case (2).
2) Insert VSS (3) with grease applied to its O-ring, then tighten
it with bolt.
Grease 99000-25010
3) Join input shaft (5), countershaft (4), low speed gear shift
shaft (2) and high speed gear shift shaft (3) assemblies all
together, then install them into right case (1).
4) Install 5th & reverse gear shift shaft (1) with 5th & reverse
gear shift guide shaft (2) into right case (5). Reverse gear
shift arm (4) has to be joined with reverse gear shift lever (3)
at the same time.
5) Place reverse gear shift lever, fasten it with bolts after apply-
ing thread lock cement.
“A” : Thread lock cement 99000-32110
Tightening torque
Revers gear shift lever bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Distance between lever end and shaft bore
“a” : 5 mm (0.2 in.)
CAUTION:
Take care not to damage oil seal lip by input shaft, or oil
leakage may take place.
NOTE:
 Input shaft right bearing on shaft can be installed into
right case by tapping shaft with plastic hammer.
 Check to make sure that counter shaft is engaged with
final gear while installing.
NOTE:
 When installing reverse gear shift lever, set it as the
following specification.

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-3
GENERAL DESCRIPTION
This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D).
The torque converter is a 3-element, 1-step and 2-phase type equipped with lock-up mechanism. The gear shift
device consists of 2 sets of planetary gear units, sets of 3 disc type clutches, 3sets of disc type brakes and one-
way clutch. The gear shift is done by selecting one of 6 positions (“P”, “R”, “N”, “D”, “2” and “L”) by means of the
select lever installed on the floor. On the shift knob, there is an overdrive (O/D) cut switch which allows shift-up
to the overdrive mode and shift-down from the overdrive mode.
1. Final gear 6. Overdrive brake (B0) 11. Oil strainer 16. Front clutch (C2)
2. Differential gear assembly 7. Direct clutch (C0) 12. Counter drive gear (Reduction gear) 17. Reverse brake (B2)
3. Parking gear 8. Rear planetary gear 13. Oil pump 18. Rear clutch (C1)
4. Counter driven gear (Reduction gear) 9. Front planetary gear 14. Input shaft 19. Differential drive pinion shaft
5. 1st and 2nd brake (B1) 10. Valve body assembly 15. Torque converter

7B-4 AUTOMATIC TRANSMISSION (4 A/T)
Item Specifications
Torque
converterType
Stall torque ratio3-element, 1-step, 2-phase type
1.65 –1.85
Oil pumpType
Drive systemInternal gear type oil pump
Engine driven
Gear
change
deviceType Forward 4-step, reverse 1-step planetary gear type
Shift position“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range
(O/D ON)Forward 1st ↔
2nd ↔
3rd ↔
4th (O/D)
automatic gear change
“D” range
(O/D OFF)Forward 1st ↔
2nd ↔
3rd ←
4th
automatic gear change
“2” range Forward 1st ↔
2nd ←
3rd automatic gear change
“L” range Forward 1st ←
2nd reduction, and fixed at 1st gear
Gear
ratio1st 2.962
2nd 1.515 Number of teeth Front sun gear : 34
Rear sun gear : 21
Front pinion gear : 16
Rear pinion gear : 19
Front internal gear : 66
Rear internal gear : 59 3rd 1.000
4th
(overdrive gear)0.737
Reverse
(reverse gear2.809
Control elementsWet type multi-disc clutch ... 3 sets
One-way clutch ... 1 set
Wet type multi-disc brake ... 3 sets
Reduction gear ratio 1.209
Final gear ratio
(Differential)3.578 (for 2WD vehicle), 3.894 (for 4WD vehicle)
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Water-cooled
Fluid used
Equivalent of DEXRON
-III or DEXRON-IIE

7B-68 AUTOMATIC TRANSMISSION (4 A/T)
DIFFERENTIAL SIDE OIL SEAL
REPLACEMENT
1) Lift up vehicle and drain transmission oil.
2) Remove drive shaft joints from differential gear of transmis-
sion.
Refer to Section 4 for procedure to disconnect drive shaft
joints.
For differential side oil seal removal, it is not necessary to
remove drive shafts from steering knuckle.
For 4WD vehicle, remove transfer referring to Section 7D.
3) Remove differential side oil seal (1) by using flat end rod or
like.
4) Install new differential side oil seal by using special tool.
Special tool
(A) : 09940-53111
(B) : 09913-75510
5) Install drive shaft referring to Section 4.
6) Refill A/T fluid referring to “FLUID CHANGE” in this section. NOTE:
For oil seal installation, press-fit oil seal so that transmis-
sion case end face is flush with oil seal end face.
2. Steering gear box
3. A/T oil pan
4. Torque converter hous-
ing
5. Transmission case