manual transmission SUZUKI SWIFT 2000 1.G Transmission Service Repair Manual

7B-106 AUTOMATIC TRANSMISSION (4 A/T)
VALVE BODY
1. Upper valve body 12. Lock-up control valve 23. Fail valve No.1
2. Upper valve body gasket 13. Lock-up control valve spring 24. Fail valve No.1 sleeve
3. Valve body plate 14. Lock-up signal valve plug 25. Key (short)
4. Lower valve body gasket 15. Lock-up signal valve 26. Key (long)
5. Lower valve body 16. Lock-up signal valve spring 27. Oil strainer
6. Primary regulator valve sleeve 17. Fail valve No.2 sleeve 28. Cooler by-pass valve
7. Primary regulator valve plunger 18. Fail valve No.2 29. Cooler by-pass valve spring
8. Primary regulator valve spring 19. Secondary regulator valve plug 30. Steel ball
9. Washer 20. Secondary regulator valve spring 31. Lock-up control valve
10. Primary regulator valve 21. Secondary regulator valve Apply automatic transmission fluid.
11. Lock-up control valve sleeve 22. Manual valve Do not reuse.

AUTOMATIC TRANSMISSION (4 A/T) 7B-107
DISASSEMBLY
Valve Body Assembly
1) Remove manual valve.
2) Remove 12 bolts from lower valve body.
Upper Valve Body
1) Remove oil strainers (1) and steel balls (2).
2) Remove keys (1).
3) Pull out all sleeves, valves, plungers, springs and washer.NOTE:
 There are 4 different kinds of bolt fixing upper and
lower valve body. Do not mix them up and remember
where they belong to.
 When separating lower and upper valve body, be care-
ful not to let the steel ball to fall off.

7B-108 AUTOMATIC TRANSMISSION (4 A/T)
Valve spring dimensions (Reference)
Lower Valve Body
1) Remove oil strainers (1).
2) Remove solenoid valves, if still attached.
3) Remove keys (2) and pull out all sleeve, plug, spring and
valves.
Valve spring dimensions (Reference)Spring Free length
“a” (mm)Outside diameter
“b” (mm)
Primary regula-
tor valve spring79.2 18.0
Lock-up control
valve spring31.1 8.5
Lock-up signal
valve spring36.1 8.5
3. Fail valve No.1 sleeve
4. Fail valve No.1
5. Cooler by-pass valve
6. Cooler by-pass valve spring
7. Manual valve
8. Secondary regulator valve
9. Secondary regulator valve spring
10. Secondary regulator valve plug
Spring Free length
“a” (mm)Outside diame-
ter “b” (mm)
Secondary regula-
tor valve spring38.7 8.8
Cooler by-pass
valve spring22.8 8.0

7B-110 AUTOMATIC TRANSMISSION (4 A/T)
Lower Valve Body
1) Apply A/T fluid to each valve, spring, sleeve and key.
Insert them, then fix with key.
2) Insert oil strainers to lower valve body.
VALVE BODY ASSEMBLY
1) Install new gasket for lower valve body (3), valve body plate
(2) and new gasket for upper valve body (1) to lower valve
body (4).
2) Make sure that steel balls (2) are at the location shown in fig-
ure. NOTE:
Make sure that the fail valve No.2 and secondary regula-
tor valve is inserted in the right direction.
NOTE:
Clean oil strainer before installing.
1. Oil strainer
2. Key (short)
3. Fail valve No.1 sleeve
4. Fail valve No.1
5. Cooler by-pass valve
6. Cooler by-pass valve spring
7. Manual valve
8. Secondary regulator valve
9. Secondary regulator valve spring
10. Secondary regulator valve plug
1. Upper valve body

AUTOMATIC TRANSMISSION (4 A/T) 7B-111
3) Assemble lower valve body with gaskets and plate over
upper valve body.
First tighten bolts A then the other bolts.
Tightening torque
Valve body bolts (a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
4) Install manual valve to valve body assembly.NOTE:
 Be careful not to fall steel balls off.
 There are four kinds of bolts fixing upper and lower
valve body. Refer to the table below for the bolt specifi-
cations.
Bolt Length “a”Pieces
A 20 mm (0.79 in.) 2
B 23 mm (0.91 in.) 2
C 29.5 mm (1.16 in.) 3
D 42 mm (1.65 in.) 5
1. Bolt A 3. Bolt C
2. Bolt B 4. Bolt D

7B-112 AUTOMATIC TRANSMISSION (4 A/T)
DIFFERENTIAL ASSEMBLY
Servicing procedure for differential assembly is similar to that for manual transmission. Refer to Section 7A of
this manual for adjustment procedure.
DISASSEMBLY
1) Remove R bearing and then speed sensor rotor using spe-
cial tool and puller.
Special tool
(A) : 09925-88210
2) Hold differential assembly with soft jawed vise, remove final
gear (1).
1. Differential pinion 7. Differential right side bearing (R bearing) 13. Pinion shaft pin
2. Differential gear
8. Speedometer sensor rotor Apply automatic transmission fluid.
3. Washer (for pinion)
9. Differential case Tightening torque
4. Pinion shaft
10. Final gear Do not reuse.
5. Washer (for gear) 11. Bolt
6. Differential side oil seal
: Apply grease 99000-25030 to oil seal lip.
12. Differential left side bearing (L bearing)
1. Differential gear assembly

AUTOMATIC TRANSMISSION (4 A/T) 7B-125
26) Attach parking lock rod (2) to manual shift shaft (1).
27) Install manual shift shaft and washer (3) to transmission
case. Fix manual shift shaft with washer, control shift lever
(4) and two nuts (5).
Apply grease to the washers.
Tightening torque
Control shift lever nuts
(a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
“A” : Grease 99000-25030
28) Install detent spring (1) to transmission case.
Tightening torque
Detent spring bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
29) Install thrust needle roller bearing (2) on counter bearing (3).
30) Install counter driven gear (1).
31) Install parking lock pawl sleeve (1) and oil plate (not shown
in figure).
Tightening torque
Parking lock pawl sleeve bolt
(a) : 19 N·m (1.9 kg-m, 14.0 lb-ft)

7B-132 AUTOMATIC TRANSMISSION (4 A/T)
56) Install valve body assembly (1) to transmission case.
First match the pin of the manual valve to the slot of the
manual shift shaft.
To fix valve body assembly (1) to transmission case, first
tighten bolt B (3), then tighten other bolts.
Tightening torque
Valve body to transmission case bolts
: 10 N·m (1.0 kg-m, 7.5 lb-ft)
57) Connect couplers of wire-to-solenoid to solenoid valves.Bolt Length “a”Pieces
A 30 mm (1.20 in.) 7
B 31 mm (1.22 in.) 2
C 25 mm (0.98 in.) 2
2. Bolt A
4. Bolt C
5. Manual valve pin
6. Slot of manual shift shaft
Solenoid Valve Wire Color
A (No.1) White
B (No.2) Black
C (No.3) Red
D (No.4) Yellow
E (No.5) Brown
TCC (Lock-up) Orange
1. Solenoid valve No.1
2. Solenoid valve No.2
3. Solenoid valve No.3
4. Solenoid valve No.4
5. Solenoid valve No.5
6. Lock-up solenoid

AUTOMATIC TRANSMISSION (4 A/T) 7B-139
REQUIRED SERVICE MATERIAL
NOTE:
This kit includes the following items.
1. Storage case, 2. Operator’s manual, 3. SUZUKI scan tool (Tech-1A), 4. DLC cable,
5. Test lead / probe, 6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
MaterialRecommended SUZUKI product
(Part Number)Use
Automatic transmission fluid
An equivalent of DEXRON
®-III or
DEXRONR
®-IIEAutomatic transmission
Parts lubrication when installing
Sealant SUZUKI BOND No. 1215
(99000-31110)Case housing star-shaped recess
bolts
(3 pcs only)
Lithium grease SUZUKI SUPER GREASE C
(99000-25030)Retaining parts in place when
assembling
Oil seal lips
D-rings
O-rings
SUZUKI SUPER GREASE A
(99000-25010)Cable ends
Converter center cup
Thread lock cement THREAD LOCK 1322
(99000-32110)Final gear bolts
Torque converter housing bolts