wheel SUZUKI SWIFT 2004 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-1
Transmission / Transaxle
Manual Transmission/Transaxle
General Description
Manual Transaxle Construction and ServicingS7RS0B5201001
The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs 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 sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is don e on input shaft and engaged with input shaft 3rd gear or
4th gear. The 5th speed synchronizer sleev e & hub on input shaft is engaged with input shaft fifth gear mounted on the
input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used.
The device utilizes the 5th synchromesh, which is the lever synchro type, to appl y the brake on the input shaft rotation.
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.
For servicing, it is ne cessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tight ened 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 reassembling.
Further, care must be taken to adjust preload of count ershaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-1
Transmission / Transaxle
Clutch
General Description
Clutch ConstructionS7RS0B5301001
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 positione d on the transaxle 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 c auses the release bearing to advance and pushes on the tips of the tapered fingers of
the diaphragm spring. When this happens, the diaphragm sp ring pulls the pressure plate away from the flywheel,
thereby interrupting the flow of drive from flywheel through clutch disc to transaxle input shaft. Clutch fluid is supplied
from brake fluid reservoir. Clutch fluid level can be checked by brake fluid level of brake fluid reservoir.
[A]: For petrol engine model2. Flywheel5. Clutch cover 8. Input shaft bearing
[B]: For diesel engine model 3. Clutch disc6. Diaphragm spring 9. Input shaft
1. Crankshaft 4. Pressure plate7. Release bearing 10. Release shaft
I4RS0A530001-01

Downloaded from www.Manualslib.com manuals search engine 5C-2 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS7RS0B5304001
Repair Instructions
Clutch Pedal InspectionS7RS0B5306001
Cylinder Push Rod Play “A”1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “A” as shown.
Push rod play
“A”: Max. 3 mm (0.12 in.)
2) If “A” is not within specification, replace master cylinder (3) or pedal arm (2). Clutch Pedal Free Travel “B”
1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“B” in figure.
Clutch pedal free travel
“B”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “B” is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.
Condition Possible cause Correction / Reference Item
Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
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.
Master cylinder piston or seal cup not
returning Replace master cylinder.
Dragging clutch Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Weakened diaphragm spring, or worn
spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle
input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
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 retainer Lubricate 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 flywheel.
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
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.

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-3
Clutch Release Margin “C”1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) dep ressed, slightly push the
shift lever to re verse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by
“C” in figure.
Clutch release margin
“C”: 25 – 55 mm (0.98 – 2.17 in.)
6) If “C” is not within specificat ion, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”. Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS7RS0B5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to reservoir cap.
Air Bleeding of Clutch SystemS7RS0B5306003
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding
operation.
Brake Fluid
Refer to reservoir cap
2) Remove bleeder plug cap from clutch operating cylinder (3). Attach a vinyl tube (1) to bleeder plug
(4), and insert the other end into container (2).
2
1
“A”
3
2
1
3
“B”
“C”
4
5
I4RS0B530001-01
I4RS0A530023-01
3 4 1
2
3
I4RS0A530003-01

Downloaded from www.Manualslib.com manuals search engine 5C-8 Clutch:
Clutch Cover, Clutch Disc and Flywheel ComponentsS7RS0B5306013
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S7RS0B5306014
Removal1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with specia l tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811
8. Clutch pedal : Apply grease 99000-25011 to outside surface of pin.
(a)
(b)
(b)
A
A
A
12
115
6
A3
A4
710
2
98
1
I4RS0A530013-02
1. Flywheel 9. Clutch disc
2. Flywheel bolt 10. Clutch cover bolt
3. Clutch release shaft seal : Apply grease 99000-25011 to seal lip. 11. Release arm
4. Clutch release shaft No.2 bush : Apply grease 99000-25011 to bush inside. 12. Release arm bolt
5. Clutch release shaft : Apply grease 99000-25011 to the end of release shaft arm. :70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
6. Clutch release shaft No.1 bush : Apply grease 99000-25011 to bush inside. :23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
7. Release bearing : Apply grease 99000-25011 to joint of bearing and release shaft and also bearing inside. Do not reuse.
8. Clutch cover
I4RS0A530014-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-9
3) Pull out input shaft bearing (1) from flywheel (2), use the following special tool if necessary.
Special tool
(A): 09921–26020
(B): 09930–30104
4) Remove flywheel (1) from crank shaft using special tool.
Special tool
(A): 09924–17811 Installation
CAUTION!
Do not reuse flywheel bolts. Otherwise, bolts
may loosen. Be sure to use new bolts with
pre-coated adhesive.

NOTE
Before assembling, make
sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (2) to crankshaft and tighten new bolts (1) to specification.
Special tool
(A): 09924–17811
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)
2) Using special tool, install input shaft bearing to flywheel (1).
Special tool
(B): 09925–98210
I2RH01530023-01
I4RS0A530015-02
I2RH01530024-01
I4RS0A530016-01

Downloaded from www.Manualslib.com manuals search engine 5C-10 Clutch:
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts, compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
4) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft li ttle by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S7RS0B5306015
Input Shaft Bearing
Check bearing (1) for smooth ro tation and replace it if
abnormality is found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to hav e reached service limit at
any of rivet holes (2), repl ace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)
I4RS0A530017-01
I4RS0A530018-01
I3RM0A530014-01
I4RS0A530019-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-11
Clutch Cover1) Check diaphragm spring (1) for abnormal wear or damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover. Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Clutch Release System Removal and
Installation
S7RS0B5306016
Removal 1) Remove release arm by loosening its bolt.
2) Take out release bearing by turning release shaft (1).
3) Drive out No.2 bush usin g special tool and hammer.
Release shaft seal will also be pushed out.
Special tool
(A): 09922–46010
4) Remove release shaft (1). 5) Install tap (M16 X 1.5) (1) to clutch release shaft
No.1 bush.
6) Pull No.1 bush out using tap (1) and special tools. Special tool
(B): 09923–46020
(C): 09930–30104
Installation 1) Drive in a new No.1 bush using special tools and
hammer, and then apply grease to bush inside.
Special tool
(A): 09943–88211
(B): 09923–46030
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
I3RM0A530015-01
I4RS0A530020-01
IYSY01531016-01
IYSY01531017-01
I3RM0A530016-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-13
Clutch Release System InspectionS7RS0B5306017
Clutch Release Bearing
Check clutch release bearing for smooth rotation. If
abnormality is found, replace it.
CAUTION!
Do not wash release bearing. Washing may
cause grease leakage and consequential
bearing damage.

Clutch Release Shaft
Check clutch release shaft and its pin for deflection or
damage.
If abnormality is found, replace it.
Specifications
Tightening Torque SpecificationsS7RS0B5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I3RM0A530020-01
I3RM0A530021-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
CPP switch lock nut 7.5 0.75 5.5 )
Clutch operating cylinder bolt 23 2.3 17.0 )
Flywheel bolt 70 7.0 51.0 )
Clutch cover bolt 23 2.3 17.0 )
Release lever bolt 23 2.3 17.0 )

Downloaded from www.Manualslib.com manuals search engine 5C-14 Clutch:
Special Tools and Equipment
Recommended Service MaterialS7RS0B5308001
NOTE
Required service material is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Special ToolS7RS0B5308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / ) / ) / )
SUZUKI Silicone Grease P/No.: 99000–25100) / )
SUZUKI Super Grease I P/No.: 99000–25210) / )
09921–26020 09922–46010
Bearing remover Clutch bush remover
)) / )
09923–36320 09923–46020
Clutch center guide (15 mm) Joint pipe
))
09923–46030 09924–17811
Joint pipe Flywheel holder
)) / ) / ) / )
09925–98210 09925–98221
Input shaft bearing inst aller Bearing installer
))
09930–30104 09943–88211
Sliding shaft Pinion bearing installer
) / ))