shaft SUZUKI SWIFT 2000 1.G Transmission Service Manual Online

AUTOMATIC TRANSMISSION (4 A/T) 7B-127
36) Inspect reverse brake (B2) piston stroke and clearance by
blowing compressed air into hole (4) shown in figure.
Make sure that the obtained piston stroke and clearance sat-
isfy the standard value.
Set dial gauge (1) to the top of reverse brake (B2) flange and
blow compressed air into the hole shown in figure.
Reverse brake disc clearance
Standard : 0.79 – 1.69 mm (0.031 – 0.067 in.)
Set special tool (B) on the tip of dial gauge and place the
other end of special tool on the claw of reverse brake (B2)
piston. Blow compressed air into the hole (4) shown in figure
and measure the value for piston stroke.
Reverse brake piston stroke
Standard : 1.77 – 2.59 mm (0.070 – 0.102 in.)
Special tool
(B) : 09952-06020
37) Apply grease to thrust washers (1) and install them to follow
shaft (2).
“A” : Grease 99000-25030 NOTE:
If clearance and/or piston stroke is out of specification,
disassemble reverse brake (B2) discs and plates, rein-
stall them to satisfy the measured values to standard
value.
2. Tip of dial gauge on the top of B2 brake flange
3. Air gun
[A] : Clearance
[B] : Piston Stroke
NOTE:
When installing thrust washers, make sure that the pro-
trusions of thrust washer do not interfere with the ones
of the other side.

7B-128 AUTOMATIC TRANSMISSION (4 A/T)
38) Install follow shaft (1) to transmission case.
Turn it right and left to match the reverse brake (B2) discs
and the spline of follow shaft.
39) Install thrust needle roller bearing (1) to intermediate shaft
(2).
40) Install intermediate shaft (1) to transmission case.
41) Install rear clutch assembly (1) by turning it right and left to
match the clutch disc of rear clutch assembly and the spline
of intermediate shaft.
42) Install thrust bearing race (2).
“A” : Grease 99000-25030
43) Install front clutch assembly (1) by turning it right and left to
match the clutch of disc clutch assembly and the spline of
follow shaft. NOTE:
When installing follow shaft, do not let the thrust washer
fall off from follow shaft.

AUTOMATIC TRANSMISSION (4 A/T) 7B-129
44) Apply grease to thrust needle roller bearing (1) and install it.
“A” : Grease 99000-25030
45) Apply grease to clutch drum thrust washer (1) and install it to
oil pump assembly (2).
“A” : Grease 99000-25030
46) Install new gasket to transmission case and install oil pump
assembly (1) to transmission case.
Tightening torque
Oil pump assembly bolts (a) : 12 N·m (1.2 kg-m, 9.0 lb-ft)
47) Measure input shaft end (2) play.
Set dial gauge (1) as shown in figure and measure the play
of the input shaft.
Input shaft end Play
Standard : 0.3 – 0.7 mm (0.012 – 0.028 in.)
48) If the obtained value is out of standard value, select thrust
bearing race (installed in step 41)) of different thickness
shown in table below and adjust the play.
Available thrust bearing race size (thickness)
1.3 mm (0.051 in.), 1.7 mm (0.067 in.) or 2.1 mm (0.083 in.)
3. Oil pump

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

7B-134 AUTOMATIC TRANSMISSION (4 A/T)
63) Install vehicle speed sensor (for speedometer) (1), shift
cable bracket (2) and connector clamp bracket (3).
Tightening torque
Vehicle speed sensor bolt
(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Shift cable bracket bolts
(b) : 13 N·m (1.3 kg-m, 9.5 lb-ft)
Connector clamp bracket bolt : 8 N·m (0.8 kg-m, 6.0 lb-ft)
64) Install A/T fluid filler tube (2) and level gauge (1).
Tightening torque
A/T fluid filler tube bolt (a) : 19.5 N·m (1.95 kg-m, 14.5 lb-ft)
65) Install output shaft speed sensor (1) and input shaft speed
sensor (2).
Apply grease to O-ring of each sensor.
Tightening torque
Output shaft speed sensor bolt
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
Input shaft speed sensor bolt
(b) : 8 N·m (0.8 kg-m, 6.0 Ib-ft)
Grease : 99000-25030
66) Install engine mounting LH bracket.
Tightening torque
Engine mounting LH bracket bolts
(a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)

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

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

7B-138 AUTOMATIC TRANSMISSION (4 A/T)
09926-96030 09926-96040 09930-30102 09931-76030
Clutch spring compressor
No.7Clutch spring compressor
No.8Sliding shaft 16/14 pin DLC adapter
09931-76011 09941-64511 09944-68510 09951-16060
Tech 1A kit
See NOTE below.Bearing remover Bearing installer Bush remover
09952-06010 09952-06020 09926-26050
Dial gauge plate No.1 Dial gauge plate No.2 Mass storage cartridge Air installer No.3
09940-53111
Oil seal install tool

7C-2 CLUTCH
GENERAL DESCRIPTION
The clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transmission input shaft with an involute spline
fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral
edge part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the
clutch release bearing is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing to advance and pushes on the tips of the tapered fin-
gers of the diaphragm spring. When this happens, the diaphragm spring pulls the pressure plate away from the
flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to transmission input shaft.
1. Crankshaft 6. Diaphragm spring
2. Flywheel 7. Release bearing
3. Clutch disc 8. Input shaft bearing
4. Pressure plate 9. Input shaft
5. Clutch cover 10. Release shaft

CLUTCH 7C-3
DIAGNOSIS
Condition Possible Cause Correction
Slipping
Improper clutch pedal free travel Adjust free travel.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel surface Replace disc, clutch cover or
flywheel.
Weakened diaphragm spring Replace clutch cover.
Rusted clutch cable Replace cable.
Dragging clutch
Improper clutch pedal free travel Adjust free travel.
Weakened diaphragm spring, or worn spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transmission input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Clutch vibration
Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly on input shaft
bearing retainerLubricate or replace input
shaft bearing retainer.
Wobbly clutch disc, or poor facing contact Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel surface Replace clutch cover or fly-
wheel.
Weakened engine mounting or loosened engine
mounting bolt or nutRetighten or replace mount-
ing.
Noisy clutch
Worn or broken release bearing Replace release bearing.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring rattling Replace clutch cover.
Grabbing clutch
Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.