4WD SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

MANUAL TRANSMISSION 7A-1
6F1
6F2
6G
6H
6K
7A1
7B1
7C1
7A
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7A
MANUAL TRANSMISSION
CONTENTS

GENERAL DESCRIPTION .............................. 7A-2
CONSTRUCTION AND SERVICING ........... 7A-2
TRANSMISSION FOR 2WD MODEL....... 7A-3
TRANSMISSION FOR 4WD MODEL....... 7A-4
DIAGNOSIS ..................................................... 7A-5
ON-VEHICLE SERVICE .................................. 7A-5
OIL CHANGE ............................................... 7A-6
DIFFERENTIAL SIDE OIL SEAL ................. 7A-6
GEAR SHIFT CONTROL LEVER AND
CABLE ......................................................... 7A-8
VEHICLE SPEED SENSOR (VSS) ............ 7A-10
UNIT REPAIR OVERHAUL ........................... 7A-11
TRANSMISSION UNIT............................... 7A-11
TRASMISSION CASE ................................ 7A-12
INPUT & COUNTER SHAFT...................... 7A-13
GEAR SHIFTER & DIFFERENTIAL ........... 7A-14
TRANSMISSION UNIT............................... 7A-16
UNIT DISASSEMBLY ................................ 7A-17
FIFTH GEARS........................................ 7A-17GEAR SHIFTER, INPUT SHAFT AND
COUNTER SHAFT................................. 7A-19
RIGHT CASE ......................................... 7A-20
SUB ASSEMBLY SERVICE ...................... 7A-21
RIGHT CASE ......................................... 7A-21
LEFT CASE............................................ 7A-21
INPUT SHAFT ASSEMBLY ................... 7A-22
COUNTER SHAFT ASSEMBLY ............ 7A-25
GEAR SHIFTER..................................... 7A-29
DIFFERENTIAL ASSEMBLY ................. 7A-30
UNIT ASSEMBLY ...................................... 7A-33
DIFFERENTIAL TO LEFT CASE ........... 7A-33
FIFTH GEARS ....................................... 7A-35
GEAR SHIFT AND SELECT SHAFT
ASSEMBLY ............................................ 7A-38
TIGHTENING TORQUE SPECIFICATION.... 7A-39
REQUIRED SERVICE MATERIAL................ 7A-40
SPECIAL TOOL ............................................ 7A-40

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).

7A-2 MANUAL TRANSMISSION
GENERAL DESCRIPTION
CONSTRUCTION AND SERVICING
The transmission provides five forward speeds and one reverse speed by means of three synchronizers and
three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and
reverse uses a sliding idler gear arrangement.
The low speed synchronizer is mounted on counter shaft and engaged with counter shaft first gear or second
gear, while the high speed synchronizer is done on input shaft and engaged with input shaft third gear or fourth
gear.
The fifth speed synchronizer on input shaft is engaged with input shaft fifth gear mounted on the input shaft.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance
of shifting to 2nd gear.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
4WD model is equipped with transfer assembly on transmission being mated to right side of differential output in
transmission.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transmission case
which is made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque
wrench. It is also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reas-
sembling.
Further, care must be taken to adjust preload of counter shaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

7A-4 MANUAL TRANSMISSION
TRANSMISSION FOR 4WD MODEL
1. 5th speed sleeve & hub 7. Reverse gear shaft 13. Countershaft 4th gear 19. Final gear
2. Input shaft 5th gear 8. Reverse idler gear 14. Countershaft 20. Differential case
3. Input shaft 4th gear 9. Input shaft 15. Countershaft 3rd gear 21. Vehicle speed sensor
4. High speed sleeve & hub 10. Right case 16. Countershaft 2nd gear 22. Transfer assembly
5. Input shaft 3rd gear 11. Side cover 17. Low speed sleeve & hub
6. Left case 12. Countershaft 5th gear 18. Countershaft 1st gear

7A-6 MANUAL TRANSMISSION
OIL CHANGE
1) Before changing or inspecting oil, be sure to stop engine and
lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage.
If leakage exists, correct it.
3) Drain old oil and fill new specified oil by specified amount (up
to level hole).
4) Apply sealant to thread of drain plug (2) and level/filler plug
(3) and torque them as specified below.
“A” : Sealant 99000-31110
Tightening torque
Transmission oil level/filler and drain plugs
(a) : 21 N·m (2.1 kg-m, 15.5 lb-ft)
Transmission oil
: API GL-4
For SAE classification, refer to viscosity chart in the fig-
ure.
Transmission oil capacity
: 2.2 liters (4.6/3.9 US/lmp. pt)
DIFFERENTIAL SIDE OIL SEAL
REPLACEMENT
1) Lift up vehicle and drain transmission oil.
2) Remove wheel, and then remove tie-rod end (1) split pin (4)
and castle nut (3).
3) Disconnect tie-rod end from knuckle (2) by using special tool.
Special tool
(A) : 09913-65210
4) Remove two stabilizer mount brackets from vehicle body.
5) Remove ball stud bolt and then separate suspension arm
from knuckle.
6) Separate transfer from transmission assembly. (for 4WD
vehicle)
For detail, refer to Section 7D. NOTE:
 It is highly recommended to use API GL-4 75W-90 gear
oil.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.
1. Drive shaft (LH)

MANUAL TRANSMISSION 7A-7
7) By using large size screwdrivers (2), pull out drive shaft joint
(1) so as to release snap ring fitting of joint spline at differen-
tial side.Pushing knuckle portion outward, detach drive shaft
at differential side.
8) Remove oil seal (1) and install a new one until it becomes
flush with case surface by using special tool and hammer.
Special tool
(A) : 09913-75510 (2WD and LH of 4WD)
(A) : 09951-46010 (RH of 4WD)
9) Apply grease to oil seal lip and at the same time check drive
shaft where oil seal contacts and make sure of its smooth-
ness.
“A” : Grease 99000-25010
10) Insert drive shaft joint to differential gear.
11) Connect ball stud with knuckle and fasten with bolt to specifi-
cation referring to Section 3D.
12) Connect tie-rod end with knuckle and fasten new nut to spec-
ified torque referring to Section 3D.
13) Install stabilizer mount brackets, fasten bolts to specified
torque referring to Section 3D.
14) Fill transmission oil as specified and make sure that oil has
been sealed with oil seal.
NOTE:
When installing oil seal, face its spring side inward.
CAUTION:
 Be careful not to scratch oil seal lip with drive shaft
joint while inserting.
 Make sure to insert drive shaft joint fully and seat its
snap ring as it was.
 Do not hit joint boot with hammer or the like. Nothing
but hands is allowed to use when inserting joint.

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

7B-12 AUTOMATIC TRANSMISSION (4 A/T)
[For 4WD model]
Gear Shift Diagram
TCC Lock-up Diagram
Shift
Throttle opening 1→
22→
33→
44→
33→
22→
1
Full throttle 40 90 143 124 80 32
Closed throttle 12 24 40 31 9 9

7B-68 AUTOMATIC TRANSMISSION (4 A/T)
DIFFERENTIAL SIDE OIL SEAL
REPLACEMENT
1) Lift up vehicle and drain transmission oil.
2) Remove drive shaft joints from differential gear of transmis-
sion.
Refer to Section 4 for procedure to disconnect drive shaft
joints.
For differential side oil seal removal, it is not necessary to
remove drive shafts from steering knuckle.
For 4WD vehicle, remove transfer referring to Section 7D.
3) Remove differential side oil seal (1) by using flat end rod or
like.
4) Install new differential side oil seal by using special tool.
Special tool
(A) : 09940-53111
(B) : 09913-75510
5) Install drive shaft referring to Section 4.
6) Refill A/T fluid referring to “FLUID CHANGE” in this section. NOTE:
For oil seal installation, press-fit oil seal so that transmis-
sion case end face is flush with oil seal end face.
2. Steering gear box
3. A/T oil pan
4. Torque converter hous-
ing
5. Transmission case

7B-76 AUTOMATIC TRANSMISSION (4 A/T)
DISMOUNTING
1) Take down transmission with engine. For its procedure, refer
to Section 6A1.
2) For 4WD vehicle, remove transfer referring to Section 7D
For 2WD vehicle, remove engine rear mounting No.1
bracket and engine rear mounting No.2 bracket with stiff-
ener.
3) Remove torque converter housing lower plate (1).
4) Remove drive plate bolts.
To lock drive plate (1), engage a flat head rod or the like (2)
with drive plate gear.
5) Remove starting motor.
6) Remove bolts and nut fastening engine and transmission,
then detach transmission from engine.
NOTE:
When detaching transmission from engine, move it in
parallel with crankshaft and use care so as not to apply
excessive force to drive plate and torque converter.
WARNING:
Be sure to keep transmission with torque converter hori-
zontal or facing up throughout the work. Should it be
tilted with torque converter down, converter may fall off
and cause personal injury.

AUTOMATIC TRANSMISSION (4 A/T) 7B-77
REMOUNTING
1) Make sure that torque converter is installed correctly to
transmission.
Refer to “UNIT ASSEMBLY” in this section.
2) Attach transmission to engine.
Tightening torque
Transmission to engine bolts and nut
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
3) Tighten drive plate-torque converter bolts.
Align drive plate bolt hole and torque converter through
starter motor mounting opening then tighten bolts through
torque converter housing lower plate opening.
Lock drive plate (1) by engaging a flat head rod or the like (2)
with drive plate gear.
Tightening torque
Drive plate to torque converter bolts
(a) : 20 N·m (2.0 kg-m, 14.5 lb-ft)
4) Install torque converter housing lower plate (1).
5) Install starter motor.
Tightening Torque
Starter motor bolts : 23 N·m (2.3 kg-m, 16.5 lb-ft)
6) For 4WD vehicle, install transfer referring to Section 7D.
For 2WD vehicle, install engine rear mounting brackets and
stiffener.
7) Remount engine with transmission assembly to vehicle.
Refer to Section 6A1 for its procedure. WARNING:
Be sure to keep transmission with torque converter hori-
zontal or facing up throughout the work. Should it be
tilted with torque converter down, converter may fall off
and cause personal injury.
3. Wrench
4. Engine oil pan