check oil SUZUKI SWIFT 2000 1.G Transmission Service Owner's Manual

AUTOMATIC TRANSMISSION (4 A/T) 7B-101
4) Remove direct clutch balancer (1) and direct clutch return
spring seat (2).
5) Remove direct clutch piston (3).
Blow compressed air through input shaft oil hole to remove
piston. If piston does not pop out, take it out with long nose
pliers.
6) Remove D-ring (4) from direct clutch No.1 drum (5).
INSPECTION
Clutch Discs, Plates and Flange
Check that sliding surfaces of discs, plates and flanges are not
worn or burnt. If necessary, replace.
Direct Clutch Return Spring Seat
Measure height of direct clutch return spring.
Height of direct clutch return spring
: 16.3 mm (0.642 in.)
.
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.
NOTE:
 Do not apply excessive force when measuring spring
height.
 Perform measurement at several points.

7B-118 AUTOMATIC TRANSMISSION (4 A/T)
2) Install new oil seal to transmission case.
Use special tool to press-fit oil seal until oil seal end face is
flush with transmission case end face.
Special tool
(F) : 09913-75510
UNIT ASSEMBLY
CAUTION:
 Automatic transmission consists of highly precise parts. As even a flaw in a 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 discs and brake band, soak them in automatic transmission fluid for
at least 2 hours.
 Be sure to use new gaskets and O-rings.
 Lubricate O-rings with automatic transmission fluid.
 Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly.
 Use yellow petrolatum grease or 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 cutouts and are installed in groove cor-
rectly.
 Do not use adhesive cements on gaskets and similar parts.
 Be sure to torque each bolt and nut to specification.

AUTOMATIC TRANSMISSION (4 A/T) 7B-135
67) Install breather sensor hose (1).
68) Install transmission range sensor (2).
Install it temporarily so that the adjustment can be done after
installing assembly back to the vehicle.
Tightening torque
Transmission range sensor bolt
(a) : 18 N·m (1.8 kg-m, 13.0 lb-ft)
69) Install torque converter (1) to input shaft.
Install torque converter, using care not to damage oil seal of
oil pump.
After installing torque converter, check to make sure that dis-
tance “a” is within specification.
Torque converter installing position
“a” : More than 19.9 mm (0.783 in.)
Check torque converter for smooth rotation.
Apply grease around cup at the center of torque converter.
“C” : Grease 99000-25010
CAUTION:
 Before installing converter, make sure that its pump
hub portion is free from nicks, burrs or damage which
may cause oil seal to leak.
 Be very careful not to drop converter on oil pump gear.
Damage in gear, should it occur, may cause a critical
trouble.
2. Flange nut
3. Torque converter housing
4. Cup

TRANSFER 7D-3
ON-VEHICLE SERVICE
OIL CHANGE
1) Before changing or inspecting oil, be sure to stop engine and
lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage
exists, correct or repair it.
3) Drain old oil, tighten drain plug (3) after applying sealant to
its thread and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
“A” : Sealant 99000-31230
Tightening torque
Transfer oil drain plug (a) : 21 N·m (2.1 kg-m, 15.5 lb-ft)
Transfer gear oil
:Hypoid gear oil API GL-5
For oil viscosity, refer to the chart.
Oil Capacity
: 0.5 liters (1.1/0.9 US/lmp. pt)
4) Torque level/filler plug (4) as specified below after applying
sealant to its thread.
“A” : Sealant 99000-31230
Tightening torque
Transfer oil level / filler plug
(b) : 21 N·m (2.1 kg-m, 15.5 lb-ft) NOTE:
 It is highly recommended to use SAE 80W-90 Hypoid
gear oil API GL-5.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.
1. Transfer
2. Drive shaft

7D-10 TRANSFER
8) Drive out pinion shaft bearing outer races (2) (front and rear)
by using brass bar (1).
COMPONENT INSPECTION
Check each bearing for smooth rotation, wear or discolora-
tion.
If found abnormal, replace.
Check oil seal for leakage and its lip for excessive hardness.
If either is found, replace.
Check transfer case for cracks.
Check bevel pinion and bevel gear for wear or cracks.
Check pinion gear and pinon shaft for wear or damage.
UNIT ASSEMBLY
Judging from faulty conditions noted before disassembly and
what is found through visual check of bearing and gear tooth etc.
after disassembly, prepare replacing parts and proceed to reas-
sembly according to procedures as described below.
REDUCTION DRIVEN GEAR
1) Drive in bevel gear to reduction driven gear.
2) Tighten bevel gear nut to specified torque while holding
bevel gear with soft jawed vise and caulk (1) nut.
Tightening torque
Transfer bevel gear nut
(a) : 150 N·m (15.0 kg-m, 108.5 lb-ft)
CAUTION:
 Bevel gear and pinion must be replaced as a set when
either replacement becomes necessary.
 When replacing taper roller bearing, replace as inner
race & outer race assembly.

TRANSFER 7D-13
To engage bevel pinion and gear correctly, it is prerequired to
install bevel pinion to transfer output retainer properly by using
adjusting shim (bevel pinion shim) as described on following
pages.
Shown in above page are relative positions of bevel pinion, gear
and transfer output retainer.
Install pinion shaft bearing (1) (front side) to bevel pinion
dummy (special tools, refer to previous page).
Install bevel pinion dummy (1), pinion shaft bearing (2) (rear
side) and special tool (A) by using special tool (B) to transfer
output retainer (refer to previous page for special tool num-
ber).
Special tool
(A) : 09922-76140
(B) : 09922-76150
(C) : 09922-76340
(D) : 09922-76430
Tighten bevel pinion nut (special tool) so that specified bear-
ing preload is obtained.
Pinion shaft bearing preload
(a) : 5.0 – 13.0 kg-cm (4.4 – 11.2 Ib-ft)
Measure height “b” in figure by using vernier caliper.
Calculate “c” by using measured value.
NOTE:
This installation requires no spacer or oil seal.
NOTE:
Before taking measurement, check for rotation by hand
more than 15 revolutions.
Distance “c”= Height “b”–Height “a”
“c”: Distance from retainer installation face to end face of bearing race
“b”: Height from retainer installation face to pinion dummy
“a”: Pinion dummy height

TRANSFER 7D-21
Tighten mounting bolt and mounting bracket bolts and nuts
to specified torque.
Tightening torque
Transfer rear mounting bracket nuts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Transfer mounting bolt
(b) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
Transfer rear mounting bracket No.2 bolts
(c) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
Tighten transfer stiffener bolts (4) to specified torque.
Tightening torque
Transfer stiffener bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Tighten exhaust pipe bolts.
Tightening torque
Exhaust pipe bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Install right side drive shaft, refer to Section 4A.
Install propeller shaft and tighten propeller shaft bolts and
center support bolts to specified torque (refer to Section 4B).
Fill gear oil to transfer as specified, refer to OIL CHANGE of
ON-VEHICLE SERVICE.
Check oil level and leakage.
(a)
(b)
(c)
1. Transmission
2. Transfer
3. Stiffener
1. Exhaust No.1 pipe
2. Exhaust No.2 pipe
1
(a)(a)2

7F-4 REAR DIFFERENTIAL
ON-VEHICLE SERVICE
OIL CHANGE
1) Before oil change or inspection, be sure to stop engine and
set vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,
correct its cause.
3) Remove level/filler plug (2) and drain plug (1), then drain old
oil.
4) Install new gasket to drain plug and tighten drain plug to
specified torque.
Tightening torque
Rear differential oil drain plug
(a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
5) Fill proper amount of new gear oil as specified below
(roughly up to level hole).
6) Install new gasket to level/filler plug and tighten level/filler
plug to specified torque.
Tightening torque
Rear differential oil level/filler plug
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Differential oil
: Hypoid gear oil API GL-5
For oil viscosity, refer to the chart.
Differential oil capacity
: 0.9 liters (1.9/1.6 US/Imp. pt)
NOTE:
 It is highly recommended to use SAE 80W-90 viscosity.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.

REAR DIFFERENTIAL 7F-7
REMOUNTING
Reverse removal procedure for installation, noting the following.
Rear Differential
Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 9900-31110
Install differential carrier assembly to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Install propeller shaft to joint flange aligning match marks (2)
and tighten propeller shaft bolts to specified torque.
Tightening torque
Propeller shaft bolts
(b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Rear Axle Shaft
For installation of rear axle shaft, refer to “REAR AXLE SHAFT
AND WHEEL BEARING INSTALLATION” in Section 3E.
Rear Brake Drum
For installation of rear brake drum, refer to “BRAKE DRUM
INSTALLATION” in Section 5.
Differential Gear Oil
Refill differential housing with new specified oil. Refer to “OIL
CHANGE” in this section for refill.
Brake Circuit Air Purging
Make sure to purge air out of brake circuit. Refer to “BLEEDING
BRAKES” in Section 5.
Then check to ensure that joint seam of pipe is free from oil leak.
UNIT DISASSEMBLY
Remove bolts (1) and separate viscous coupling case from differ-
ential carrier.1

REAR DIFFERENTIAL 7F-9
7) Remove coupling case oil seal by using special tool.
Special tool
(C) : 09913-50121
INSPECTION
Check companion flange for wear of damage.
Check bearing for wear or discoloration.
Check coupling case for cracks.
Check rear differential input flange for wear damage.
ASSEMBLY
Reverse disassembly procedure for assembly, note the followings
Tighten companion flange nut to specified torque by using
special tool and caulk nut.
Tightening torque
Rear differential companion flange nut
(a) : 130 N·m (13.0 kg-m, 94.0 lb-ft)
Special tool
(A) : 09930-40113
Tighten rear differential input flange bolt (1) to specified
torque.
Tightening torque
Rear differential input flange bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Use new oil seal
Apply grease (12–15 g / 0.42–0.53 oz) to oil seal lip portion
and companion flange, where daubed in black as shown in
figure.
“A” : Grease 99000-25010
Apply grease (0.3–0.5 g / 0.01–0.02 oz) to oil seal dust lip
portion as shown in figure.
“B” : Grease 99000-25010
(C)
(a)
(A)
1, (a)