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

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

AUTOMATIC TRANSMISSION (4 A/T) 7B-19
TABLE 2 (MECHANICAL)
Condition Possible Cause Correction
Vehicle does not move
at any rangeManual valve faulty Clean or replace.
Primary regulator valve faulty Clean or replace.
No gear
change
1st
↔
↔↔ ↔ 2nd
Shift solenoid -D (No.4) and/or -E (No.5)
stuck Clean or replace.
2nd
↔
↔↔ ↔ 3rd
Shift solenoid -A (No.1), -C (No.3) and/or fail
valve No.1 stuckClean or replace.
3rd
↔
↔↔ ↔ 4th
Shift solenoid -B (No.2), -C (No.3) and/or fail
valve No.2 stuckClean or replace.
Harsh engagement
P, N
→
→→ → R
Front clutch accumulator faulty Clean or replace.
N
→
→→ → D
1st & 2nd brake accumulator faulty Clean or replace.
1st
→
→→ → 2nd at D
range or 2 rangeFront clutch accumulator faulty Clean or replace.
Shift solenoid -D (No.4) Clean or replace.
2nd
→
→→ → 3rd at D
rangeDirect clutch accumulator faulty Clean or replace.
Shift solenoid -E (No.5) Clean or replace.
3rd
→
→→ → 4th at D
rangeOverdrive brake accumulator faulty Clean or replace.
Shift solenoid -B (No.2) Clean or replace.
All gear change
Primary regulator valve faulty Clean or replace.
Excessive slip
(low line pressure)Primary regulator valve faulty Clean or replace.
Vehicle does not
move at
1st, 2nd, 3rd and
reverse gearRear clutch faulty Repair or replace.
Reverse gear
Reverse brake faulty Repair or replace.
2nd, 3rd and 4th
gearFront clutch faulty Repair or replace.
3rd and 4th gear
Direct clutch faulty Repair or replace.
1st and 2nd gear
1st & 2nd brake faulty Repair or replace.
4th gear
Overdrive brake faulty Repair or replace.
Any forward and
reverse gearParking lock pawl faulty Repair or replace.
Shock or engine stalls
when starting off and
stoppingTCC (lock-up clutch) faulty Inspect and replace as necessary.
TCC (lock-up) solenoid faulty Clean or replace.
Lock-up control valve faulty Clean or replace.
Lock-up signal valve faulty Clean or replace.
No up-shift
1st
→
→→ → 2nd
Front clutch faulty Repair or replace.
2nd
→
→→ → 3rd
Direct clutch faulty Repair or replace.
3rd
→
→→ → 4th
Overdrive brake faulty Repair or replace.
No engine
braking
2nd or 3rd gear
Front, rear or direct clutch or 1st & 2nd brake
faultyRepair or replace
L range 1st gear
Direct clutch or 1st & 2nd brake faulty Repair or replace.
No lock-up
Torque converter clutch faulty Inspect and replace as necessary.
Lock-up control valve faulty Clean or replace.
TCC (lock-up) solenoid faulty Clean or replace.
Secondary regulator valve faulty Clean or replace.
Signal valve faulty Clean or replace.

7B-20 AUTOMATIC TRANSMISSION (4 A/T)
STALL TEST
This test is to check overall performance of automatic transmis-
sion and engine by measuring stall speed at “D” and “R” ranges.
Be sure to perform this test only when transmission fluid is at nor-
mal operating temperature and its level is between FULL and
LOW marks.
1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to “P”.
4) Depress brake pedal fully.
5) Shift select lever to “D” and depress accelerator pedal fully
while watching tachometer. Read engine rpm quickly when it
has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is
checked.
7) In the same way, check stall speed in “R” range.
8) Stall speed should be within following specification.
Stall speed
: 2,750 – 3,150 r/min CAUTION:
 Do not run engine at stall more than 5 seconds contin-
uously, for fluid temperature may rise excessively
high.
 After performing stall test, be sure to leave engine run-
ning at idle for longer than 30 seconds before another
stall test.
Test result Possible cause
Lower than
standard levelLack of engine output
Defective torque converter
Higher than
standard level
in “D” rangeLow line pressure
Malfunctioning 1st & 2nd brake
Malfunctioning rear clutch
Malfunctioning stator one-way clutch
Higher than
standard level
in “R” rangeLow line pressure
Malfunctioning rear clutch
Malfunctioning reverse brake
Malfunctioning stator one-way clutch
Malfunctioning direct clutch

7B-28 AUTOMATIC TRANSMISSION (4 A/T)
DTC TABLE
DTC NO.
“O/D OFF” Lamp
Flashing Pattern of DTC
(Not using scan tool)DETECTING ITEMSMIL
Using
scan toolNot using
scan toolVehicle
equipped
with
immobi-
lizer indi-
cator lampVehicle
equipped
without
immobi-
lizer indi-
cator lamp
–12 Normal––
P0715 14Input/Turbine speed sensor circuit
malfunction1 driving
cycleNot
applicable
P0730 18 Incorrect gear ratio2 driving
cyclesNot
applicable
P075321
Shift solenoid-A (No.1) electrical1 driving
cycleNot
applicable
22
P075823
Shift solenoid-B (No.2) electrical1 driving
cycleNot
applicable
24
P0763 43 Shift solenoid-C (No.3) electrical1 driving
cycleNot
applicable
P0768 45 Shift solenoid-D (No.4) electrical1 driving
cycleNot
applicable
P0773 48 Shift solenoid-E (No.5) electrical1 driving
cycleNot
applicable
P074325
Torque converter clutch (lock-up)
system electrical1 driving
cycleNot
applicable
26

AUTOMATIC TRANSMISSION (4 A/T) 7B-29
P0741 29Torque converter clutch (lock-up)
solenoid performance or stuck off2 driving
cyclesNot
applicable
P0720 31Output shaft speed sensor circuit
malfunction1 driving
cycleNot
applicable
P170032
Throttle position signal input mal-
function1 driving
cycleNot
applicable
33
P0705 34Transmission range sensor circuit
malfunction1 driving
cycleNot
applicable
P0725 35Engine speed input circuit malfunc-
tion2 driving
cyclesNot
applicable
P071036
Transmission temperature sensor
circuit malfunction2 driving
cyclesNot
applicable
38
P1709 51Engine coolant temperature signal
circuit1 driving
cycleNot
applicable
P0702
52Transmission control system elec-
trical1 driving
cycleNot
applicable
P1702 Internal malfunction of TCMDTC NO.
“O/D OFF” Lamp
Flashing Pattern of DTC
(Not using scan tool)DETECTING ITEMSMIL
Using
scan toolNot using
scan toolVehicle
equipped
with
immobi-
lizer indi-
cator lampVehicle
equipped
without
immobi-
lizer indi-
cator lamp

AUTOMATIC TRANSMISSION (4 A/T) 7B-37
DTC P0741 (DTC NO.29) TCC (LOCK-UP) SOLENOID PERFORMANCE OR STUCK OFF
Step Action Yes No
1Was “AUTOMATIC TRANSMISSION DIAG-
NOSTIC FLOW TABLE” performed?Go to Step 2. Go to “AUTOMATIC
TRANSMISSION DIAG-
NOSTIC FLOW TABLE”.
2 Check TCC (lock-up) solenoid referring to
“SHIFT SOLENOID VALVES” in this section.
Is it in good condition?Go to Step 3. Replace TCC (lock-up)
solenoid.
3 Check valve body for fluid passage clog, or
lock-up control valve, secondary regulator valve
or signal valve stuck, referring to “TRANSMIS-
SION UNIT REPAIR OVERHAUL” in this sec-
tion.
Are they in good condition?Go to Step 4. Faulty valve body.
4 Substitute a known-good torque converter and
recheck.
Is it OK?Torque converter mal-
function.Overhaul and repair auto-
matic transmission.
DTC DETECTING CONDITION
Difference between turbine rev. and engine rev. too close even though TCM ordered to turn OFF lock-up.
Difference between turbine rev. and engine rev. too wide even though TCM ordered to turn ON lock-up.

7B-56 AUTOMATIC TRANSMISSION (4 A/T)
FLUID LEVEL AT ROOM TEMPERATURE
INSPECTION
The fluid level check at room temperature performed after repair
or fluid change before test driving is just preparation for level
check of normal operation temperature. The checking procedure
itself is the same as that described previously. If the fluid level is
between FULL COLD and LOW COLD, proceed to test drive. And
when the fluid temperature has reached the normal operating
temperature, check fluid again and adjust it as necessary.
FLUID CHANGE
1) Lift up vehicle.
2) When engine has cooled down, remove drain plug (1) from
oil pan and drain A/T fluid.
3) Install drain plug.
Tightening torque
A/T fluid drain plug (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft)
1. Dipstick
2.“FULL HOT” mark
3.“LOW HOT” mark
4.“FULL COLD” mark
5.“LOW COLD” mark

AUTOMATIC TRANSMISSION (4 A/T) 7B-59
INSTALLATION
1) Using flat tip screwdriver, turn transmission range sensor to
have the match marks (1) line up (transmission range sensor
“N” range).
2) Turn selector lever (1) to “N” range (to have the automatic
transmission to “N” range).
3) Install transmission range sensor (1) to transmission case.
Tightening torque
Transmission range sensor bolt
(a) : 18 N·m (1.8 kg-m, 13.0 lb-ft)
4) Move selector lever in cabin to each range and check the
continuity of each terminal of transmission range sensor
referring to “INSPECTION”.
5) Connect transmission range sensor coupler.
6) Check that the engine can only be started in “N” and “P”
range, but can not in “D”, “2”, “L” or “R” range. Also, check
that backup lamp come ON at “R” range.