transmission SUZUKI SWIFT 2000 1.G Transmission Service Service Manual

MANUAL TRANSMISSION 7A-41
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7A-42 MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION (4 A/T) 7B-1
6F1
6F2
6G
6H
6K
7A
7A1
7C1
7D
7B
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7B
AUTOMATIC TRANSMISSION (4 A/T)
CONTENTS
GENERAL DESCRIPTION ...............................7B-3
ELECTRONIC SHIFT CONTROL SYSTEM . 7B-6
TRANSMISSION CONTROL MODULE
(TCM) ........................................................ 7B-7
FAIL SAFE FUNCTION ............................. 7B-8
CHANGE MECHANISM .......................... 7B-10
AUTOMATIC GEAR SHIFT DIAGRAM ... 7B-11
DIAGNOSIS ....................................................7B-13
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE ...................... 7B-13
TROUBLE DIAGNOSIS TABLE .................. 7B-18
STALL TEST ........................................... 7B-20
TIME LAG TEST ..................................... 7B-21
LINE PRESSURE TEST ......................... 7B-22
ENGINE BRAKE TEST ........................... 7B-23
“P” RANGE TEST.................................... 7B-23
ELECTRONIC CONTROL SYSTEM
DIAGNOSIS ................................................ 7B-24
PRECAUTIONS IN DIAGNOSING
TROUBLES ............................................. 7B-24
DTC CHECK ........................................... 7B-25
DTC CLEARANCE .................................. 7B-27
DTC TABLE............................................. 7B-28
TCM POWER AND GROUND CIRCUIT
CHECK .................................................... 7B-30
DTC P0715 (DTC NO.14) INPUT/
TURBINE SPEED SENSOR CIRCUIT
MALFUNCTION ...................................... 7B-31
DTC P0730 (DTC NO. 18) INCORRECT
GEAR RATIO .......................................... 7B-33
DTC P0753 (DTC NO.21/22) SHIFT
SOLENOID-A (NO.1) ELECTRICAL ....... 7B-35DTC P0758 (DTC NO.23/24) SHIFT
SOLENOID-B (NO.2) ELECTRICAL ....... 7B-35
DTC P0743 (DTC NO.25/26) TCC
(LOCK-UP CLUTCH) SYSTEM
ELECTRICAL .......................................... 7B-35
DTC P0741 (DTC NO.29) TCC
(LOCK-UP) SOLENOID
PERFORMANCE OR STUCK OFF ........ 7B-37
DTC P0720 (DTC NO. 31) OUTPUT
SHAFT SPEED SENSOR CIRCUIT
MALFUNCTION ...................................... 7B-38
DTC P1700 (DTC NO.32/33)
THROTTLE POSITION SIGNAL INPUT
MALFUNCTION ...................................... 7B-41
DTC P0705 (DTC NO.34)
TRANSMISSION RANGE SENSOR
(SWITCH) CIRCUIT MALFUNCTION ..... 7B-43
DTC P0725 (DTC NO.35) ENGINE
SPEED INPUT CIRCUIT
MALFUNCTION ...................................... 7B-45
DTC P0710 (DTC No.36/38)
TRANSMISSION TEMPERATURE
SENSOR CIRCUIT MALFUNCTION ...... 7B-47
DTC P0763 (DTC NO.43) SHIFT
SOLENOID-C (NO.3) ELECTRICAL ....... 7B-49
DTC P0768 (DTC NO.45) SHIFT
SOLENOID-B (NO.4) ELECTRICAL ....... 7B-49
DTC P0773 (DTC NO.48) SHIFT
SOLENOID-E (NO.5) ELECTRICAL ....... 7B-49
DTC P1709 (DTC NO.51) ENGINE
COOLANT TEMPERATURE/BAROMETRIC
PRESSURE SIGNAL CIRCUIT............... 7B-51 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

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-5
FUNCTIONS
TABLE OF COMPONENT OPERATION
TABLE OF SHIFT SOLENOID VALVE OPERATION
NOTE:
For operation of each part, refer to TABLE OF COMPONENT OPERATION.
PART NAME FUNCTION
Rear clutch Meshes input shaft and rear sun gear through one-way clutch.
Front clutch Meshes input shaft and front internal gear and rear carrier.
Overdrive brake Fixes rear sun gear.
1st & 2nd brake Fixes front sun gear.
Reverse brake Fixes front internal gear and rear carrier.
Direct clutch Meshes input shaft and rear sun gear.
Selector
positionGear
positionPar t
P
R
N
1st
2nd
3rd
4th(O/D)
1st
2nd
1st D
2
LRear
clutchFront
clutchOverdrive
brake1st & 2nd
brakeReverse
brakeDirect
clutchOne-way
clutch
:Operating:Not operating
:Operating:Not operating Range & Gear
P, N
R
D, 21st gear of,
L
1st gear of
2nd gear
3rd gear
4th gearShift Solenoid Valve
A (No.1) B (No.2) C (No.3) D (No.4) E (No.5)

7B-6 AUTOMATIC TRANSMISSION (4 A/T)
ELECTRONIC SHIFT CONTROL SYSTEM
1. Engine 15. O/D off switch F. Range signal
2. Transmission 16. Combination meter (O/D off lamp) G. O/D off switch signal
3. TCM 17. A/C compressor G’. O/D off lamp signal
4. ECM 18. Brake lamp switch H. A/C clutch signal
5. Input shaft speed sensor (Turbine rev. sensor) 19. Monitor connector NO. 2 I. Brake signal
6. Transmission temp. sensor (A/T fluid temp. sensor) 20. Suzuki scan tool J. Diagnosis switch signal
7. TCC solenoid (Lock-up solenoid) 21. Ignition switch K. Serial communication with Suzuki scan tool
8. Shift solenoid-A (Shift solenoid No.1) 22. Battery L. Power supply
9. Shift solenoid-B (Shift solenoid No.2) 23. A/T relay M. Throttle opening signal
10. Shift solenoid-C (Shift solenoid No.3) A. Turbine speed signal N. Engine coolant temp./Barometric pressure signal
11. Shift solenoid-D (Shift solenoid No.4) B. A/T fluid temp signal O. Idle up signal
12. Shift solenoid-E (Shift solenoid No.5) C. TCC (lock-up) control signal P. A/T failure signal
13. Output shaft speed sensor (A/T VSS) D. Shift control signal Q. Engine speed (rev.) signal.
14. Transmission range sensor (Shift switch) E. A/T output shaft speed signal
14
3
19
15
1816
14 13 5
2
7
9
12
8
6
10 17
11

AUTOMATIC TRANSMISSION (4 A/T) 7B-7
TRANSMISSION CONTROL MODULE (TCM)
TCM is an electronic circuit component that controls gear shift, idle-up according to the signal from each sensor.
Also it has learning control function for performing optimum control. It is a microcomputer consisting of an IC,
transistor, diode, etc. It is installed behind glove box.
1.“O/D OFF” lamp (in combination meter) 11. Backup lamp 21. Dropping resistor
2.“O/D” off switch 12. Shift indicator (if equipped) 22. Output shaft speed sensor (A/T VSS)
3. Monitor connector No.2 13. A/T 23. Input shaft speed sensor (Turbine rev. sensor)
4. Brake lamp 14. Transmission temperature sensor
(A/T fluid temp. sensor)24. A/T power source relay
5. Brake lamp switch 15. Shift solenoid-A (Shift solenoid No.1) 25. Ignition switch
6. ECM 16. Shift solenoid-B (Shift solenoid No.2) 26. DLC
7. A/C clutch 17. Shift solenoid-C (Shift solenoid No.3) 27. Barometric pressure sensor
8. Transmission range sensor (Shift switch) 18. Shift solenoid-D (Shift solenoid No.4) 28. Solenoid power relay
9. Shift lock solenoid switch (if equipped) 19. Shift solenoid-E (Shift solenoid No.5) 29. Terminal arrangement of TCM coupler
(Viewed from harness side)
10. Shift lock solenoid (if equipped) 20. TCC solenoid (Lock-up solenoid)
C41-14
C41-21
C42-5
C41-23
G02-16
BLKBLKLT GRN/ RED/BLU BLU/ORN
PPL/YEL
3
45
+BB
GRN/WHT
LT BLU
PPL
WHT/BLK
BLK/WHT
BRN
PNK/BLK 6
7
8
C44-8
C43-8
C44-18
C44-20
C43-5
C44-5
910
ORN
RED
GRN/ORN RED/BLK
GRNC43-1
C43-2
C43-3
C43-9
C43-10
C43-11 GRN/YEL
BLU/WHT P
R
N
D
2
L11
12C44-21
C44-17
C43-4
C44-4
12V 12V
12V
12V
12V IG1
IG115V
5VC44-3
C44-16
C44-10
C44-23
C44-24
C44-25
C44-26
C44-22
C44-11
C44-12
C44-13
C43-6
C43-14
C43-13
C43-7
C43-15
C44-2
C44-15
C43-12
BLU BLUBLK
BLK BLK
BLU/YEL
YEL/BLK RED/WHT WHT BLU/ORN RED/BLU GRY/BLU
BLK/YEL WHT/BLU
BRN/WHT BRN/WHT BRN WHT/RED
BLK/YEL
BRN/YEL BLU/RED
GRY/RED13
14
15
16
17
19
20 BRN
21
22
23
+BB 24
25
26
12V
12V
12V
12V
18
12V
IG1
IG11
5V
1
2
28
27

7B-8 AUTOMATIC TRANSMISSION (4 A/T)
FAIL SAFE FUNCTION
This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve,
sensor or its circuit fails.
The table below shows the fail safe function for each fail condition of sensor, solenoid or its circuit.
Area Detecting condition Fail safe function
Input/Turbine
speed sensor cir-
cuit
(DTC P0715)Input shaft speed
sensor signal voltage
is too high or too low.When vehicle running and in shift change by automatic elec-
tronic control, gear is fixed to gear which is going to be
selected and lock-up function is turned OFF.
When vehicle running and in no shift change, gear is fixed to
gear right before the trouble occurred and lock-up function is
turned OFF.
When vehicle is at stop after or during detecting trouble, or in
shift change by manual operation while running, gear is fixed
as the followings and lock-up function is turned OFF.
“P” range →
P, “R” range →
R, “N” range →
N,
“D” range →
3rd, “2” range →
2nd, “L” range →
1st Output shaft speed
sensor circuit
(DTC P0720)Output shaft speed
sensor signal voltage
is too high or too low.
Shift solenoid
(DTC P0753)
(DTC P0758)
(DTC P0763)
(DTC P0768)
(DTC P0773)Solenoid output
voltage is too high
although TCM
orders solenoid to
turn off.
Solenoid output
voltage is too low
although TCM
orders solenoid to
turn on.When select lever is “P”, “R”, “N”, “D” or “2” range, A/T sole-
noid power relay is turned OFF and gear is fixed as follows :
“P” range →
P, “R” range →
R, “N” range →
N,
“D” range →
3rd
When select lever is “2” range, gear is fixed to pre pro-
grammed gear position of several patterns as follows :
–Malfunction of No.1 solenoid →
3rd
–Malfunction of No.2 solenoid →
3rd
–Malfunction of No.3 solenoid →
2nd
–Malfunction of No.4 solenoid →
1st or 2nd
–Malfunction of No.5 solenoid →
2nd or 3rd
–Malfunction of 2 or more solenoids →
3rd
When select lever is “L” range, gear is fixed to pre pro-
grammed gear position of several patterns as follows :
–Malfunction of No.1 solenoid →
3rd
–Malfunction of No.2 solenoid →
1st
–Malfunction of No.3 solenoid →
2nd
–Malfunction of No.4 solenoid →
1st or 2nd
–Malfunction of No.5 solenoid →
1st
–Malfunction of 2 or more solenoids →
3rd
TCC circuit
(DTC P0743)Lock-up function is turned OFF.