Front hub SUZUKI SWIFT 2005 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 2C-2 Rear Suspension:
Repair Instructions
Rear Wheel Alignment InspectionS7RS0B2306017
Measure toe and camber referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
NOTE
Rear suspension is not adjustable structure.

Rear toe (total)
: IN 3.8 ± 3.8 mm (IN 0.1969 ± 0.1969 in)
Rear camber
: –1 ° ± 1
If measured value is out of specified value, check
following items for damage, deformation and crack.
• Rear axle (torsion beam)
• Spindle, wheel hub or wheel bearing
• Vehicle body
Rear Shock Absorber Removal and InstallationS7RS0B2306001
Removal 1) Hoist vehicle and remove rear wheels.
2) Remove tail end member trim (1) and quarter inner trim (2).
3) Support rear axle by using floor jack to prevent it from lowering.
4) Remove shock absorber lower nut.
5) Remove shock absorber upper nut. Then remove shock absorber, a pair of upper washers and lower
washer. Installation
1) Install shock absorber (1), a pair of upper washers (2) and lower washer.
Tighten new rear shock absorber upper nut (4) and
lower nut temporarily at this step.
CAUTION!
Never reuse the removed rear shock
absorber upper nut.

NOTE
A pair of upper washers (2) are installed as
shown in figure.

3. Clip
3
3 2
3
1
3
I7RS0B230001-01
3. Body panel
14
3 2
I6RS0C230005-01

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-7
Installation1) Install disc to wheel hub.
2) Install caliper assemb ly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening torque
Caliper carrier bolt (a): 85 N·m (8.5 kgf-m, 61.5
lb-ft)
4) Torque front wheel nuts to specification. Tightening torque
Wheel nut (b): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
5) Upon completion of installation, perform brake test.Front Brake Disc InspectionS7RS0B4206009
• Install wheel nuts to hub bolts and fasten to fix the brake disc.
Using magnetic stand and with dial gauge positioned
at about 10 mm (0.39 in.) inward from periphery of
disc, measure deflection of disc.
If limit value is exceeded, replace correct or replace.
Front brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Special tool
(A): 09900–20607
(B): 09900–20701
• Using micrometer, measure thickness of brake disc. If it is less than limit, replace brake disc.
Front brake disc thickness
Standard: 20.0 mm (0.79 in.)
Limit: 18.0 mm (0.71 in.)
I2RH01420028-01
I2RH01420026-01
I2RH01420027-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-34
Rear Wheel Speed Sensor InspectionS7RS0B4506009
Refer to “Front Wheel Speed Sensor Inspection” since
rear wheel speed sensor is the same as front wheel
speed sensor.
Front Wheel Encoder On-Vehicle InspectionS7RS0B4506010
Before inspect front wheel encoder, remove front drive
shaft or front wheel spindle referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, cl ean encoder or replace wheel
bearing. Refer to “Front Wheel Hub, Steering Knuckle
and Wheel Bearing Removal and Installation in
Section 2B”.
Front wheel Encoder Removal and InstallationS7RS0B4506011
CAUTION!
Front wheel encoder is included in front
wheel bearing. If front wheel encoder needs
to replaced, replace it as a front wheel
bearing.

For removal and installation of front wheel bearing,
referring to “Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation in Section 2B”.
Rear Wheel Encoder On-Vehicle InspectionS7RS0B4506012
Before inspect rear wheel encoder, hoist vehicle and
remove wheel.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, clean encoder or replace rear
wheel hub assembly. Refer to “Rear Wheel Hub
Removal and Installati on in Section 2C”.
Rear Wheel Encoder Removal and InstallationS7RS0B4506013
CAUTION!
Rear wheel encoder is included in rear wheel
hub assembly. If rear wheel encoder needs to
replaced, replace it as a rear wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Removal and
Installation in Section 2C”.
1
I5JB0A450034-01
1
I6RS0B460038-03

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-33
2Check wheel speed sensor circuit
1) Turn ignition switch OFF.
2) Disconnect connector from ESP ® control module and
applicable wheel speed sensor coupler.
3) Check for proper connection of ESP ® control module
and wheel speed sensor coupler.
4) If connections are OK, che ck wheel speed sensor circuit
for the following.
• Resistance of both ESP ® control module connector
(1) terminals a pair of app licable sensor terminals is
no continuity (circuit short check)
• Resistance of applicable sensor terminal of ESP ®
control module connector and vehicle body ground is
no continuity (ground short check)
• Resistance of applicable sensor terminal of ESP ®
control module connector and corresponding terminal
of wheel speed sensor connector (2) in main harness
(for front sensor) or floor harness (for rear sensor) is
continuity (continuity check)
• Voltage of applicable sensor terminal of ESP ® control
module connector and vehicle body ground is 0 V with
ignition switch turned ON (power short check)
Are they in good condition? Go to Step 3. Repair or replace
defective circuit.
3 Check wheel speed sensor
1) Remove applicable wheel speed sensor.
2) Check sensor for damage or foreign material attached.
Is it in good condition? Go to Step 4. Clean, repair or replace.
4 Check wheel encoder
1) Check front and/or rear wheel encoder for the following
(remove front drive shaft and/or rear wheel hub
assembly):
• Encoder surface neither crack nor damaged
• No foreign material being attached
• Encoder not being eccentric
• Wheel bearing free from excessive play
Are they in good condition? Go to Step 5. Clean, repair or replace
front wheel bearing and/
or rear wheel hub
assembly.
5 Check wheel speed sensor installing condition
1) Install wheel speed sensor to knuckle.
2) Tighten sensor bolt to specified torque and check that
there is no clearance between sensor and knuckle.
Is it OK? Go to Step 6. Replace wheel speed
sensor.
Step Action Yes No
1
2“E85-2”“E85-3”“E85-5”
“E85-6”
“E85-11”
“E85-12”
“E85-14”
“E85-15”
I6RS0B460017-02

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-61
Front Wheel Encoder On-Vehicle InspectionS7RS0B4606033
Before inspect front wheel encoder, remove front drive
shaft or front wheel spindle referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, cl ean encoder or replace wheel
bearing. Refer to “Front Wheel Hub, Steering Knuckle
and Wheel Bearing Removal and Installation in
Section 2B”.
Front Wheel Encoder Removal and InstallationS7RS0B4606034
CAUTION!
Front wheel encoder is included in front
wheel bearing. If front wheel encoder needs
to replaced, replace it as a front wheel
bearing.

For removal and installation of front wheel bearing,
referring to “Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation in Section 2B”.
Rear Wheel Encoder On-Vehicle InspectionS7RS0B4606035
Before inspect rear wheel encoder, hoist vehicle and
remove wheel.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, cl ean encoder or replace rear
wheel hub assembly. Refer to “Rear Wheel Hub
Removal and Installati on in Section 2C”.
Rear Wheel Encoder Removal and InstallationS7RS0B4606036
CAUTION!
Rear wheel encoder is included in rear wheel
hub assembly. If rear wheel encoder needs to
replaced, replace it as a rear wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Removal and
Installation in Section 2C”.
Master Cylinder Pressure Sensor On-Vehicle
Inspection
S7RS0B4606016
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Check that basic brake system other than ESP ®
refer to “Brakes Diagnosi s Note in Section 4A”.
3) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
1
I5JB0A450034-01
1
I6RS0B460038-03
(A)
1
I4RS0B450003-01

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 Automatic Transmission/Transaxle: 5A-157
38) After applying A/T fluid to intermediate shaft thrust bearing rear race (3), thrust bearing (2) and front
race (1), install them to forward and reverse clutch
assembly (4).
Bearing race dimension
39) Apply A/T fluid to forward and reverse clutch assembly (1).
Install forward and revers e clutch assembly while
rotating clockwise and co unterclockwise frequently
to fit clutch discs to mating hubs.
NOTE
Before installation, align teeth of forward and
reverse clutch discs to facilitate installation.

40) Check for correct installation of forward and reverse clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
forward and reverse clutch assembly, forward clutch
hub, rear planetary sun gear subassembly and one-
way clutch No.1 assemb ly, and reinstall them
properly.
Distance between forward and reverse clutch
assembly and mating surface of transaxle case
“a”: Less than 29.4 mm (1.157 in.)
41) After applying A/T fluid to O/D and 2nd coast brake retaining plate (4), separator plate (3), discs (2) and
rear plate (1), install th em to transaxle case (5).
Front race Rear race
Outside
diameter 30.6 mm (1.20 in.) 28.2 mm (1.11 in.)
Thickness 2.0 mm (0.08 in.) 2.0 mm (0.08 in.)
I2RH0B510294-01
I2RH0B510295-01
“a”
“a”
1 2
I2RH0B510296-01
I2RH0B510297-01

Downloaded from www.Manualslib.com manuals search engine 5A-160 Automatic Transmission/Transaxle:
55) After applying A/T fluid to input shaft front thrust bearing (1), install it to direct clutch assembly (2).
56) Apply A/T fluid to direct clutch assembly (1). Install direct clutch a ssembly while rotating
clockwise and counterclockwise frequently to fit
clutch discs to mating hub.
NOTE
Before installation, align teeth of direct clutch
discs to facilitate installation.

57) Check for correct installation of direct clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
direct clutch assembly, direct clutch hub and reinstall
them properly.
Distance between direct clutch assembly and
mating surface of transaxle case
“a”: 10.4 – 11.4 mm (0.409 – 0.449 in.) 58) Install oil pump assembly
(1) to transaxle case.
Tightening torque
Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
59) Make sure that input shaft (1) turns smoothly.
I2RH0B510308-01
I2RH0B510309-01
“a”
“a”
1
2
I2RH0B510310-01
I2RH0B510311-01
I2RH0B510312-01

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 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.