Check oil SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-97
Installation1) Apply A/T fluid to input shaft speed sensor O-ring.
2) Install input shaft speed se nsor (1) to A/T case and
tighten bolt to specified torque.
Tightening torque
Input shaft speed sensor bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
3) Connect input shaft speed sensor connector (2) to input shaft speed sensor (1).
4) Connect negative cable to battery.
Input Shaft Speed Sensor InspectionS7RS0B5106019
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Check resistance between input shaft speed sensor (1) terminals.
Input shaft speed sensor resistance
Standard: 560 – 680 Ω at 20 °C (68 °F)
Transmission Fluid Temperature Sensor
Removal and Installation
S7RS0B5106020
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) With engine is cool, remove drain plug and drain A/T fluid.
4) Install drain plug. Refer to “A/T Fluid Change”.
5) Remove A/T oil pan.
6) Remove oil stra iner assembly. 7) Remove valve body assembly referring to
“Automatic Transaxl e Unit Disassembly”.
CAUTION!
When pulling solenoid wire harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

8) Remove solenoid wire harness (1).
Installation
Reverse removal procedure to install solenoid wire
harness and valve body assembly noting the following
points.
• For details of valve body assembly and their connectors installation, refer to “Automatic Transaxle
Unit Assembly”.
• For details of A/T oil pa n installation, refer to
“Automatic Transaxle Unit Assembly”. Use new oil
pan gasket.
• Tighten valve body harness connector bolt to specified torque.
Tightening torque
Valve body harness connector bolt (a): 7.0 N·m (
0.7 kgf-m, 5.0 lb-ft)
• Pour A/T fluid and check fluid level according to procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
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Downloaded from www.Manualslib.com manuals search engine 5A-98 Automatic Transmission/Transaxle:
Transmission Fluid Temperature Sensor
Inspection
S7RS0B5106021
Warm up transmission fluid temperature sensor (2).
Check resistance between terminals of valve body
harness connector (1). Thus make sure its resistance
decrease as its temperature increase.
Transmission fluid temperature sensor resistance
10 °C (50 °F): 5.8 – 7.1 k Ω
110 °C (230 °F): 231 – 263 Ω
145 °C (293 °F): 105 – 117 Ω
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation
S7RS0B5106022
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N· m (1.7 kgf-m, 12.5 lb-ft)
5) Remove A/T oil pan (1) and oil pan gasket (2).
6) Remove oil strain er assembly (3). 7) Remove transmission fluid temperature sensor (1)
from sensor clamp.
8) Disconnect solenoid connectors (2).
9) Remove shift solenoid va lve-A (No.1) (1), shift
solenoid valve-B (No.2) (2) and timing solenoid valve
(3) by removing bolts.
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-99
Installation1) Install shift solenoid valve- A (No.1) (1), shift solenoid
valve-B (No.2) (2) and timing solenoid valve (3).
Tightening torque
Shift solenoid bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-
ft)
2) Connect solenoid connectors identifying their installing positions by wire color.
3) Install transmission fluid sensor (6) and sensor wire to clamp. 4) Install oil strain
er assembly (1).
Tightening torque
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
5) Install new oil pan gasket (1) and oil pan (2).
6) Tighten oil pan bolts to specified torque diagonally and little by little.
Tightening torque
Oil pan bolt (b): 7.0 N·m (0.7 kgf-m, 5.0 lb-ft)
Solenoid Valves (Shift Solenoid Valves, and
Timing Solenoid Valve) Inspection
S7RS0B5106023
Resistance Check
Check shift solenoid valves and timing solenoid valve.
Shift solenoid valves and timing solenoid valve
resistance
Standard: 11 – 15 Ω at 20 °C (68 ° F)
Solenoid coupler Wire color
Shift solenoid valv e-A (No.1) (2) White
Shift solenoid valv e-B (No.2) (3) Black
Timing solenoid valve (1) Yellow
TCC pressure control solenoid
valve (4) Light green / Brown
Pressure control solenoid valve (5) Green / Gray
1 2
3
(a)
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3 5
4
6
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-101
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Pressure Control
Solenoid) Removal and Installation
S7RS0B5106024
Removal1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
5) Remove A/T oil pan (1) and oil pan gasket (2).
6) Remove oil strain er assembly (3).
7) Remove transmission fluid temperature sensor (1) from sensor clamp.
8) Disconnect solenoid connectors (2). 9) Remove valve body assembly referring to
“Automatic Transaxl e Unit Disassembly”.
10) Remove pressure control solenoid valve and TCC pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC pressure control solenoid va lve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body asse mbly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “A utomatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valve InspectionS7RS0B5106025
CAUTION!
• Be very careful as dust etc. does enter when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
Installation
Reverse removal procedure noting the following.
• Connect TCM connectors securely.
• If the vehicle is equipped with air bag system, be sure to enable air bag system after TCM is back in place.
Refer to “Enabling Air Bag System in Section 8B”.
A/T Relay InspectionS7RS0B5106027
1) Disconnect negative cable at battery.
2) Remove A/T relay (2) from fuse and relay box (1).
3) Check that there is no continuity between terminal “C” and “D”.
If continuity is indicated, replace A/T relay.
4) Connect battery positive (+ ) terminal to terminal “A”
of A/T relay and battery negative (–) terminal to
terminal “B” of A/T relay.
Check continuity between terminal “C” and “D” of A/T
relay.
If continuity does not indicated, replace A/T relay.
Differential Side Oil Seal ReplacementS7RS0B5106028
1) Lift up vehicle and drain automatic transaxle fluid.
2) Remove drive shaft joints from differential gear of transaxle. Refer to “Front Drive Shaft Assembly
Removal and Installation in Section 3A” for
procedure to disconnect drive shaft joints.
For differential side oil seal removal, it is not
necessary to remove drive shafts from steering
knuckle.
3) Remove differential side oil seal (1) by using screwdriver or the like.
"D"
"B" "A"
"C"
1
2
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Downloaded from www.Manualslib.com manuals search engine 5A-104 Automatic Transmission/Transaxle:
4) Apply grease to new differential side oil seal lips.: Grease 99000–25030 (SUZUKI Super Grease C)
5) Install new differential side oil seals (1) by using special tool.
Special tool
(C): 09944–88220
(D): 09924–74510
Differential side oil seal installing depth
Right side “a”: 2.6 – 3.6 mm (0.10 – 0.14 in.)
Left side “b”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
6) Install drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”.
7) Pour A/T fluid referring to “A/T Fluid Change”.
A/T Fluid Cooler Hoses ReplacementS7RS0B5106029
The rubber hoses for the A/T fluid cooler should be
checked at specified interval. If replacing them, be sure
to note the following.
• to replace clamps at the same time
• to insert hose as far as its limit mark
• to clamp clamps securely
[A]: Right side [B]: Left side
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1. Inlet hose (Outlet from A/T fluid cooler)
2. Outlet hose (Inlet to A/T fluid cooler)
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Downloaded from www.Manualslib.com manuals search engine A u to m a tic Tra n s m is s io n /Tra n s a x le : 5 A -1 0 9
1. Torque converter37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing : Apply sealant 99000-31230 to mating
surface to transaxle case. 38. Cooler check valve
74. Rear sun gear thrust bearing race
3. Oil strainer assembly : Replace oil strainer when overhauling. 39. Spring
75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely. 84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal : Apply grease 99000-25030 to oil seal
lip. 49. Reduction drive gear
85. Rear cover seal ring
14. Differential side oil seal : Apply grease 99000-25030 to oil seal
lip. 50. Planetary ring gear subassembly
86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly 93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc : Do not reuse.
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Apply automatic transaxle fluid.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 23 N⋅m (2.3 kgf-m, 17 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 25 N⋅m (2.5 kgf-m, 18 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face. : 7.5 N
⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 22 N⋅m (2.2 kgf-m, 16 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 7 N⋅m (0.7 kgf-m, 5.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 17 N⋅m (1.7 kgf-m,12.5 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 29 N⋅m (2.9 kgf-m, 21 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-118 Automatic Transmission/Transaxle:
55) Remove one-way clutch outer race retainer (1).
56) Check one-way clutch No.2 as follows.• Ensure planetary carrier (1) rotates only in counterclockwise direction “A”, never in clockwise
direction “B”.
• If the planetary carrier rotates both ways or does not rotate either way, one-way clutch No.2
assembly will need to be replaced with new one-
way clutch No.2 assembly.
57) Remove one-way clutch No.2 assembly (1). 58) Remove planetary gear assembly (1).
59) Measure 1st and reverse brake piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace discs and plates.
• Using special tool, measure 1st and reserve brake piston stroke when compressed air (400 – 800
kPa, 4 – 8 kg/cm
2, 57 – 113 psi) is blown through
oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.79 – 1.49 mm (0.031 – 0.059 in.)
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Downloaded from www.Manualslib.com manuals search engine 5A-122 Automatic Transmission/Transaxle:
Oil Pump Assembly Disassembly and
Reassembly
S7RS0B5106035
Disassembly1) Remove O-ring from pump body.
2) Remove 8 oil pump subassembly bolts (1) and stator shaft assembly (2).
3) Remove oil seal (1) using special tool. Special tool
(A): 09913–50121
Reassembly 1) Install new oil pump body oil seal (1). Use special tool and hammer to install it, and then
apply grease to its lip portion.
Special tool
(A): 09913–85210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C) 2) Install driven gear and drive gear to oil pump body
after applying A/T fluid.
3) Install stator shaft assembly to oil pump body and tighten 8 pump subassembly bolts (1) to
specification.
Tightening torque
Oil pump subassembly bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
4) After applying A/T fluid to new O-ring, install it to oil pump body.
5) Check drive gear for smooth rotation by using torque converter (1).
Oil Pump Assembly InspectionS7RS0B5106036
1) Check body clearance of driven gear (1).Push driven gear to one side of oil pump body (2).
Using a feeler gauge, m easure clearance between
driven gear and body. If clearance exceeds its
standard value, replace oil pump assembly.
Clearance between oil pump driven gear and oil
pump body
Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.)
2. Oil pump body
2. Oil pump body
2 1
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-123
2) Check tip clearance of both drive and driven gears.Using a feeler gauge, m easure clearance between
drive and driven gear tips. If clearance exceeds its
standard value, replace oil pump assembly.
Tip clearance between oil pump drive gear and
oil pump driven gear
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
3) Check side clearance of both gears. Using a straightedge (1) and a feeler gauge (2),
measure side clearance between gears and pump
body.
If clearance exceeds its standard value, replace oil
pump assembly.
Side clearance between gears and oil pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.0019 in.)
4) Using special tool, measure stator shaft bush (1) bore.
If measured stator shaft bush bore is out of
specifications, replace oil pump assembly with new
one.
Special tool
(A): 09900–20605
Stator shaft bush bore
Standard: 18.424 – 18.450 mm (0.7254 – 0.7264
in.) 5) Install direct clutch asse
mbly (1) to stator shaft
assembly (2), then ensure that direct clutch
assembly turns smoothly.
If unsmooth rotation or noise are found in oil pump
assembly, replace oil pump assembly with new one.
This check should also be done to input shaft
assembly and replace input shaft assembly if
necessary.
6) Using special tool, measure oil pump body bush bore.
If measured oil pump body bush (1) bore is out of
specifications, replace o il pump assembly with new
one. Torque converter also needs to be checked.
Replace torque converter, if necessary.
Special tool
(A): 09900–20605
Oil pump body bush bore
Standard: 38.113 – 38.138 mm (1.5005 – 1.5015
in.)
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