wheel bolts SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

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.

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.

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-5
UNIT DISMOUNTING
1) Disconnect negative cable at battery.
2) Hoist vehicle and remove wheels.
3) Drain transmission oil.
4) Remove exhaust No.1 pipe (1).
5) Remove propeller shaft.
6) Remove right side drive shaft (1) refer to Section 4A.
7) Remove Stiffener (3).
8) With transmission assembly held on jack, remove rear
mounting bolts (1).
9) Remove transfer mounting bolts and draw out transfer
assembly from transmission assembly.
2. Exhaust No.2 pipe
12
1
1. Transfer
2. Transmission
1

7F-6 REAR DIFFERENTIAL
DIFFERENTIAL UNIT
DISMOUNTING
1) Hoist vehicle and remove wheels.
2) Drain oil from rear differential. (Refer to “OIL CHANGE” in
this section.)
3) Remove brake drum and disconnect parking brake cable
from brake back plate.
4) Remove axle shafts, refer to “REAR AXLE SHAFT AND
WHEEL BEARING REMOVAL” in Section 3E.
5) Before removing propeller shaft, give match marks (1) on
joint flange and propeller shaft as shown.
6) Remove differential carrier bolts and differential assembly
with viscous coupling case.
1. Drain plug
2. Level plug
1

REAR DIFFERENTIAL 7F-7
REMOUNTING
Reverse removal procedure for installation, noting the following.
Rear Differential
Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 9900-31110
Install differential carrier assembly to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Install propeller shaft to joint flange aligning match marks (2)
and tighten propeller shaft bolts to specified torque.
Tightening torque
Propeller shaft bolts
(b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Rear Axle Shaft
For installation of rear axle shaft, refer to “REAR AXLE SHAFT
AND WHEEL BEARING INSTALLATION” in Section 3E.
Rear Brake Drum
For installation of rear brake drum, refer to “BRAKE DRUM
INSTALLATION” in Section 5.
Differential Gear Oil
Refill differential housing with new specified oil. Refer to “OIL
CHANGE” in this section for refill.
Brake Circuit Air Purging
Make sure to purge air out of brake circuit. Refer to “BLEEDING
BRAKES” in Section 5.
Then check to ensure that joint seam of pipe is free from oil leak.
UNIT DISASSEMBLY
Remove bolts (1) and separate viscous coupling case from differ-
ential carrier.1