5A- SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-139
2) Install reduction driven gear (1) with special tools and hydraulic press.
Special tool
(A): 09913–84510
(B): 09925–88210 3) Install countershaft LH bearing (1) with special tools
and hydraulic press.
Special tool
(A): 09913–84510
(B): 09925–88210
Valve Body Assembly ComponentsS7RS0B5106052
I2RH0B510213-01
I2RH0B510214-01
I4RS0A510044-01
1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid.
2. Shift solenoid valve-A (No.1) 7. Valve body assembly: 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Shift solenoid valve-B (No.2) 8. Manual valve: Do not reuse.
4. TCC pressure control solenoid valve 9. Solenoid lock plate
5. Timing solenoid valve 10. O-ring

Downloaded from www.Manualslib.com manuals search engine 5A-140 Automatic Transmission/Transaxle:
Valve Body Assembly Disassembly and
Reassembly
S7RS0B5106053
CAUTION!
When replacing pressure control solenoid
valve and/or TCC pressure control solenoid
valve, it is strictly required to replace it
together with valve body assembly as a set.
Replacing pressure control solenoid valve
and/or TCC pressure control solenoid valve
independently may cause excessive shift
shock.

Disassembly1) Pull out manual valve (1).
2) Remove pressure cont rol solenoid valve (1).
3) Remove TCC pressure control solenoid valve (1). 4) Remove shift solenoid valve-A (1).
5) Remove shift solenoid valve-B (1).
6) Remove timing solenoid valve (1).
7) Remove temperature sensor clamp (1).
2. Solenoid lock plate
I2RH0B510216-01
I2RH0B510217-01
1
I4RS0A510045-01
I2RH0B510219-01
I2RH0B510220-01
I2RH0B510221-01
I2RH0B510222-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-141
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Shift solenoid valve-A and -B are identical
• After applying A/T fluid to new O-rings, fit them to solenoid valves, then insta ll solenoid valves to valve
body.
• Tighten solenoid valve bolts to specified torque
Tightening torque
Solenoid valve bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Solenoid valve bolt specification
Differential Assembly ComponentsS7RS0B5106054
Bolt Length “a” Pieces
A (1) 49 mm (1.93 in.) 5
B (2) 20 mm (0.79 in.) 1
C (3) 60 mm (2.36 in.) 1
1
1
1
3
2
"a"
I4RS0A510046-01
I2RH0B510224-01
1. Differential side RH bearing 5. Side bearing shim: Apply automatic transaxle fluid.
2. Output shaft speed sensor drive gear 6. Final gear bolt: Tightening torque
3. Differential case subassembly 7. Side bearing cup: Do not reuse.
4. Final gear 8. Differential side LH bearing

Downloaded from www.Manualslib.com manuals search engine 5A-142 Automatic Transmission/Transaxle:
Differential Assembly Disassembly and
Reassembly
S7RS0B5106055
Disassembly1) Remove final gear bolts (1), and then final gear (2).
2) Remove differential side RH bearing by using special tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
3) Remove output shaft speed sensor drive gear (1). 4) Remove differential side LH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
Reassembly
WARNING!
• When taking warmed final driven gear out of vessel, use tongs or the like. Taking out
it with bare hand will cause severe burn.
• While installing warme d final driven gear,
use oven glove such as leather glove.
Picking up it with bare hand may cause
burn.

CAUTION!
Do not leave final driven gear in boiling water
for longer than 5 min. Overheating the gear
may cause strength reduction of gear.

1) Put final driven gear in water vessel, heat and remove when it boils, then remove moisture.
NOTE
After removing moisture on final driven gear,
install final driven gear to differential case as
quickly as possible.

2. Differential case subassembly
I2RH0B510225-01
I2RH0B510226-01
I2RH0B510227-01
I2RH0B510228-01
I2RH0B510229-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-143
2) As shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case.
3) Tighten final gear bolts (1) to specified torque.
NOTE
To avoid rust, apply A/T fluid to final driven
gear after installation.

Tightening torque
Final gear bolt (a): 78 N·m (7.8 kgf-m, 56.5 lb-ft)
4) After applying A/T fluid to output shaft speed sensor drive gear (1), install output shaft speed sensor drive
gear.
5) Install new differential side RH bearing (1) by using special tool and hydraulic press.
NOTE
Replace differential side RH bearing together
with bearing cup as a set.

Special tool
(A): 09913–70123 6) Install new differential side LH bearing (1) by using
special tool and hydraulic press.
NOTE
Replace differential side LH bearing together
with bearing cup as a set.

Special tool
(A): 09913–70123
Differential Assembly InspectionS7RS0B5106056
1) Hold differential case subassembly with soft jawed
vice and set special tools as shown.
Special tool
(A): 09900–20607
(B): 09900–20701
2) Measure differential gear thrust play.
Differential gear thrust play
Standard: 0.05 – 0.20 mm (0.002 – 0.008 in.)
3) If thrust play is out of specification, replace differential case subassembly.
2. Final driven gear
I2RH0B510230-01
I2RH0B510231-01
I2RH0B510232-01
I2RH0B510233-01
I2RH0B510234-01
I2RH0B510235-01

Downloaded from www.Manualslib.com manuals search engine 5A-144 Automatic Transmission/Transaxle:
Torque Converter Housing Disassembly and
Reassembly
S7RS0B5106057
Disassembly1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2).
2) Remove lubrication LH tube (1) and RH tube (2).
NOTE
Do not bend lubrication tube with excessive
force.

3) Remove differential side oil seal (1). 4) Remove countershaft RH bearing cup by using
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
5) Remove differential side RH bearing cup by using special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
6) Remove torque converter case plugs (1).
I2RH0B510236-01
I2RH0B510237-01
I2RH0B510238-01
I2RH0B510239-01
I2RH0B510240-01
I2RH0B510241-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-145
Reassembly1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque
converter housing.
Tightening torque
Torque converter housing plug (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
2) Using special tools, assemble differential side RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
3) Using special tool, install countershaft RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
4) Using special tools, install new differential side oil seal to torque converter housing.
Special tool
(A): 09924–74510
(B): 09944–88220 Differential side oil seal installing depth
“a”: 2.6 – 3.6 mm (0.10 – 0.14 in.)
5) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
6) Install lubrication LH tube (1) and RH tube (2).
7) Install fluid reservoir RH plate (1) and lubrication tube clamp (2).
Tightening torque
Lubrication tube clamp bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
Fluid reservoir RH plate bolt (b): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
I2RH0B510242-01
(A)
(B)
I3RM0B510063-01
(B) (A)
I3RM0B510064-01
I2RH0B510245-02
I2RH0B510237-01
I2RH0B510246-01

Downloaded from www.Manualslib.com manuals search engine 5A-146 Automatic Transmission/Transaxle:
Transaxle Case Disassembly and ReassemblyS7RS0B5106058
Disassembly1) Remove differential side oil seal (1).
2) Remove countershaft LH bearing cup and shim with special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
3) Remove differential side LH bearing cup and shim with special tools.
Special tool
(A): 09944–96011
(B): 09942–15511 Reassembly
1) Using special tools, assemb le shim and differential
side LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
2) Using special tools, assemble shim and countershaft LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
I2RH0B510247-01
I2RH0B510248-01
I2RH0B510249-01
(B)
(A)
I3RM0B510065-01
(B) (A)
I3RM0B510066-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

I2RH0B510252-01
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01

Downloaded from www.Manualslib.com manuals search engine 5A-148 Automatic Transmission/Transaxle:
One-way clutch No.1 assembly1) Install one-way clutch No.1 assembly (2) to rear planetary sun gear subassembly (1).
2) Securing rear planetary sun gear subassembly, ensure that one-way clutch No.1 assembly rotates
only in one direction.
If the one-way clutch rotates in both directions or it
does not rotate in either direction, replace it with new
one.
Adjustment
Differential side bearing preload 1) After applying A/T fluid to differential assembly, fit it to transaxle case.
2) Install torque converter housing to transaxle case, then tighten bolts (1) to specified torque.
Tightening torque
Torque converter housing bolt (a): 29 N·m (2.9
kgf-m, 21 lb-ft) 3) Measure bearing preload (a) by using a special tool.
Special tool
(A): 09928–06050
Differential side bearing preload (a) measured as
starting torque
In the case of new bearing: 0.78 – 1.37 N ⋅m (7.9 –
13.9 kg-cm, 0.58 – 1.01 lb-ft)
In the case of reused bearing: 0.39 – 0.69 N ⋅m
(3.9 – 6.9 kg-cm, 0.29 – 0.51 lb-ft)
4) If bearing preload is out of specification, select shim with suitable thickness from among the list below
and replace it. Then adjust differential side bearing
preload within specification.
Available shim thickness
NOTE
Record measured differential side bearing,
because it is necessary to adjust
countershaft bearing preload.

5) Remove differential assembly.
I2RH0B510254-01
I2RH0B510255-01
Thickness Identification mark
1.80 mm (0.070 in.) A
1.85 mm (0.072 in.) B
1.90 mm (0.074 in.) C
1.95 mm (0.076 in.) D
2.00 mm (0.078 in.) E
2.05 mm (0.080 in.) F
2.08 mm (0.081 in.) G
2.11 mm (0.083 in.) H
2.14 mm (0.084 in.) J
2.17 mm (0.085 in.) K
2.20 mm (0.087 in.) L
2.23 mm (0.088 in.) M
2.26 mm (0.089 in.) N
2.29 mm (0.090 in.) P
2.32 mm (0.091 in.) Q
2.35 mm (0.092 in.) R
2.40 mm (0.094 in.) S
2.45 mm (0.096 in.) T
2.50 mm (0.098 in.) U
2.55 mm (0.100 in.) V
2.60 mm (0.102 in.) W
2.65 mm (0.104 in.) X
2.70 mm (0.106 in.) Y
I2RH0B510256-01