torque SUZUKI SWIFT 2000 1.G Transmission Service Repair Manual

7B-136 AUTOMATIC TRANSMISSION (4 A/T)
TIGHTENING TORQUE SPECIFICATION
Fastening partTightening torque
Nm kg-m lb-ft
A/T fluid drain plug 23 2.3 16.5
Transmission rage sensor bolt 18 1.8 13.0
Output shaft speed sensor bolt 8 0.8 6.0
Input shaft speed sensor bolt 8 0.8 6.0
Dropping resistor bolts 20 2.0 14.5
Shift solenoid bolts 8 0.8 6.0
Transmission temperature sensor bolt 10 1.0 7.5
Transmission to engine bolts and nut 85 8.5 61.5
Drive plate to torque converter bolts 20 2.0 14.5
Starter motor bolts 23 2.3 16.5
Oil pump cover bolts 10 1.0 7.5
Valve body bolts 5.5 0.55 4.0
Final gear bolts 90 9.0 65.0
Counter drive gear installing bolts 5.5 0.55 4.0
Rear cover bolts 19 1.9 14.0
Control shift lever nuts 30 3.0 22.0
Detent spring bolt 11 1.1 8.0
Parking lock pawl sleeve bolt 19 1.9 14.0
Parking lock pawl bolts 11 1.1 8.0
Oil pump assembly bolts 12 1.2 9.0
Torque converter housing bolts 19 1.9 14.0
Wire-to-solenoid assembly bolt 8 0.8 6.0
Valve body to transmission case bolts 10 1.0 7.5
A/T oil pan bolts 7.5 0.75 5.5
A/T oil cooler bolt 60 6.0 43.5
Vehicle speed sensor bolt 5.5 0.55 4.0
Shift cable bracket bolt 13 1.3 9.5
Connector clamp bracket bolt 8 0.8 6.0
A/T fluid filler tube bolt 19.5 1.95 14.5
Engine mounting LH bracket bolts 55 5.5 40.0

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

CLUTCH 7C-1
6F1
6F2
6G
6H
6K
7A1
7B1
7C1
7D
7E
7C
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7C
CLUTCH
CONTENTS
GENERAL DESCRIPTION .............................. 7C-2
DIAGNOSIS ..................................................... 7C-3
ON-VEHICLE SERVICE .................................. 7C-4
CLUTCH CABLE .......................................... 7C-4
CLUTCH PEDAL AND CLUTCH PEDAL
BRACKET .................................................... 7C-6
CLUTCH PEDAL HEIGHT ....................... 7C-7
CLUTCH PEDAL FREE TRAVEL ............ 7C-7UNIT REPAIR OVERHAUL ............................. 7C-8
CLUTCH COVER, CLUTCH DISC AND
FLYWHEEL.................................................. 7C-8
CLUTCH RELEASE SYSTEM ................... 7C-11
TIGHTENING TORQUE SPECIFICATION.... 7C-14
REQUIRED SERVICE MATERIAL................ 7C-14
SPECIAL TOOL ............................................ 7C-14

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).

7C-4 CLUTCH
ON-VEHICLE SERVICE
CLUTCH CABLE
REMOVAL
1) Disconnect negative cable at battery.
2) Remove clutch cable joint nut (1).
3) Remove joint pin (2) from clutch release lever (3).
4) Disconnect cable hook (1) from clutch pedal (4).
5) Remove clutch cable (3) from bracket (5) by turning cable
cap (2) about 90° as shown.
1. Clutch cable 6. Pedal bracket
2. Release lever 7. Adjusting bolt
3. Joint pin
: Apply grease 99000-25010 to joint pin.8. Lock nut
4. Joint nut 9. Clutch cable hook
: Apply grease 99000-25010 to cable hook.
5. Clutch pedal Tightening torque

7C-6 CLUTCH
CLUTCH PEDAL AND CLUTCH PEDAL BRACKET
1. Clutch cable hook
: Apply grease 99000-25010 to cable
hook.7. Pedal spring
: Apply grease 99000-25010 to inside surface
of spring.13. Adjusting bolt cap
2. Clutch pedal bracket 8. Pedal shaft spacer
: Apply grease 99000-25010 to outside sur-
face of spacer.14. Adjusting bolt
3. Bolt 9. Pedal shaft 15. Lock nut
4.
Nut10.
Clutch pedalTightening torque
5. Pedal shaft nut 11. Pedal pad
6. Pedal bush 12. Pedal return cushion

7C-8 CLUTCH
UNIT REPAIR OVERHAUL
CLUTCH COVER, CLUTCH DISC AND FLYWHEEL
REMOVAL
1) Dismount transmission assembly referring to Section 7A.
2) Hold flywheel stationary with special tool (A) and remove
clutch cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A) : 09924-17810
1. Flywheel7. Release bearing
: Apply grease 99000-25010 to joint of bearing and release
shaft and also bearing inside. (0.3 g)
2. Clutch release shaft seal
: Apply grease 99000-25010 to seal lip. (0.3 g)8. Clutch cover
3. Clutch release shaft No.2 bush
: Apply grease 99000-25010 to bush inside. (0.3 g)9. Clutch disc
4. Return spring 10. Clutch cover bolt
5. Clutch release shaft
Apply grease 99000-25010 to the end of release shaft arm. (0.3 g)Tightening torque
6. Clutch release shaft No.1 bush
: Apply grease 99000-25010 to bush inside. (0.3 g)Do not reuse.

7C-10 CLUTCH
INSTALLATION
1) Install flywheel (1) to crankshaft and tighten bolts (2) to spec-
ification.
Special tool
(A) : 09924-17810
Tightening torque
Flywheel bolts (a) : 70 N·m (7.0 kg-m, 50.5 lb-ft)
2) Using special tool, install input shaft bearing to flywheel.
Special tool
(B) : 09925-98210
3) Aligning clutch disc to flywheel center by using special tool,
install clutch cover (1) and bolts. Then tighten bolts to speci-
fication.
Special tool
(A) : 09924-17810
(C) : 09923-36320
Tightening torque
Clutch cover bolts (b) : 23 N·m (2.3 kg-m, 16.5 lb-ft) NOTE:
Before assembling, make sure that flywheel surface and
pressure plate surface have been cleaned and dried thor-
oughly.
NOTE:
 While tightening clutch cover bolts, compress clutch
disc with special tool (C) by hand so that disc cen-
tered.
 Tighten cover bolts little by little evenly in diagonal
order.

CLUTCH 7C-13
3) Apply grease to No.2 bush (1) inside and press-fit it by using
the same special tool as in removal.
“A” : Grease 99000-25010
Special tool
(C) : 09922-46010
4) Coat grease to shaft seal (2) lip and then install it till it is flush
with case surface. Use special tool for this installation and
face seal lip downward (inside).
“A” : Grease 99000-25010
Special tool
(D) : 09925-98221
5) Caulk seal at A by using caulking tool and hammer.
6) Hook return spring.
7) Apply grease to release bearing (1) inside and release shaft
arm (2), then set bearing.
“A” : Grease 99000-25010
8) Apply small amount of grease to input shaft (3) spline (0.3 g)
and front end (0.15 g) as well.
“B” : Grease 99000-25210
9) Set release lever to release shaft aligning their punch marks
(1), then tighten bolt.
Tightening torque
Release lever bolt (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft)

7C-14 CLUTCH
TIGHTENING TORQUE SPECIFICATION
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
Fastening partTightening torque
Nm kg-m lb-ft
Flywheel bolts 70 7.0 50.5
Clutch cover bolts 23 2.3 16.5
Release lever bolt 23 2.3 16.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Cable end hook and joint pin.
Release shaft bushes and seal.
Release shaft arm.
Release bearing inside.
SUZUKI SUPER GREASE I
(99000-25210)Input shaft spline and front end.
09921-26020 09922-46010 09923-36320 09923-46020
Bearing remover Bush remover Clutch center guide Joint pipe
09923-46030 09924-17810 09925-98210 09925-98221
Joint pipe Flywheel holder Input shaft bearing
installerBearing installer

TRANSFER 7D-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7E
7F
7D
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7D
TRANSFER
CONTENTS
GENERAL DESCRIPTION ...............................7D-2
DIAGNOSIS ......................................................7D-2
ON-VEHICLE SERVICE ...................................7D-3
UNIT REPAIR OVERHAUL ..............................7D-4
UNIT DISMOUNTING ...................................7D-5
UNIT DISASSEMBLY ...................................7D-6
TRANSFER ASSEMBLY...........................7D-6
REDUCTION DRIVEN GEAR ...................7D-7
INTERMEDIATE SHAFT ...........................7D-8
TRANSFER OUTPUT RETAINER ............7D-9
COMPONENT INSPECTION ......................7D-10
UNIT ASSEMBLY .......................................7D-10REDUCTION DRIVEN GEAR ................. 7D-10
BEVEL GEAR SHIM ............................... 7D-11
TRANSFER OUTPUT RETAINER .......... 7D-12
RIGHT CASE .......................................... 7D-16
LEFT CASE............................................. 7D-17
TRANSFER ASSEMBLY ........................ 7D-17
BEVEL GEAR BACK LASH .................... 7D-18
UNIT INSTALLATION ................................. 7D-20
TIGHTENING TORQUE SPECIFICATION..... 7D-22
REQUIRED SERVICE MATERIAL................. 7D-22
SPECIAL TOOL ............................................. 7D-22