oil drain plug SUZUKI SWIFT 2005 2.G Service User Guide

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)
I2RH0B510054-01
1 2I4RS0A510027-01
1
I2RH01510071-01

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-167
Specifications
Tightening Torque SpecificationsS7RS0B5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
A/T fluid drain plug 171.7 12.5 ) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor bolt 131.3 9.5 ) / )
Input shaft speed sensor bolt 5.5 0.55 4.0)
Valve body harness connector bolt 7.00.7 5.0 )
Shift solenoid bolt 111.1 8.0 )
Oil strainer bolt 101.0 7.5 ) / )
Oil pan bolt 7.00.7 5.0 ) / )
Transaxle and engine fastening bolt and nut 85 8.5 61.5)
Drive plate to torque converter bolt 252.5 18.0 )
Transaxle stiffener bolt 555.5 40)
Starter motor bolt and nut 505.0 36.5 )
Oil pump subassembly bolt 101.0 7.5 )
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 111.1 8.0 )
Final gear bolt 787.8 56.5 )
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 292.9 21) / ) / )
Manual detent spring bolt 101.0 7.5 )
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 252.5 18.0 )
Fluid reservoir LH plate bolt 101.0 7.5 )
Oil pump assembly bolt 252.5 18.0 )
Transaxle case plug 7.5 0.75 5.5)
Valve body harness connector bolt 5.5 0.55 4.0)
Valve body bolt 111.1 8.0 )
Fluid outlet union 252.5 18.0 )
Fluid cooler pipe union bolt 222.2 16.0 )
Fluid cooler pipe bracket bolt 101.0 7.5 )
Fluid filler tube bolt 101.0 7.5 )
Input shaft speed sensor bolt 111.1 8.0 )
Harness bracket bolt 232.3 17.0 )
Select cable clamp bolt 101.0 7.5 )
Transmission range sensor lock nut 70.7 5.0 )
Manual select lever nut 131.3 9.5 )
Engine mounting LH bracket bolt 555.5 40.0
)

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-3
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS7RS0B5204001
Repair Instructions
Manual Transaxle Oil ChangeS7RS0B5206001
1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil. 5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Pour new specified oil unt il oil level reaches bottom
of oil filler plug hole (3) as shown in figure.NOTE
It is highly recommended to use API GL-4
75W-90 gear oil.

Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Manual transaxle oil capacity
Reference: 2.0 liters (4.2/3.5 US/Imp. pt)
Condition Possible cause Correction / Reference Item
Gears slipping out of
mesh Worn shift fork shaft
Replace.
Worn shift fork or synchronizer sleeve Replace.
Weak or damaged locating springs Replace.
Worn bearings on input shaft or
countershaft Replace.
Worn chamfered tooth on sleeve and
gear Replace sleeve and gear.
Hard shifting Maladjusted gear select control cable Adjust.
Inadequate or insufficient lubricant Replenish.
Improper clutch pedal free travel Replace clutch master cylinder or clutch pedal
arm.
Distorted or broken clutch disc Replace.
Damaged clutch pressure plate Replace clutch cover.
Worn synchronizer ring Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve or gear.
Worn gear shift / select control cables
joint Replace.
Distorted shift shaft Replace.
Worn gear shift / select control cables Replace.
Noise Inadequate or insufficient lubricant Replenish.
Damaged or worn bearing(s) Replace.
Damaged or worn gear(s) Replace.
Damaged or worn synchronizer parts Replace.

Downloaded from www.Manualslib.com manuals search engine 5B-4 Manual Transmission/Transaxle:
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Differential Side Oil Seal ReplacementS7RS0B5206002
1) Lift up vehicle and drain transaxle oil.
2) Remove front drive shaft and/or center shaft referring to “Front Driv e Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
4) Install oil seal (1) facing its spring side inward. Use special tool and hammer for installation.
Special tool
(A): 09913–85210
5) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make
sure of its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
6) Insert front drive shaft and/or center shaft referring to “Front Drive Shaft A ssembly Removal and
Installation in Section 3A”.
7) Fill transaxle oil as specified referring to “Manual Transaxle Oil Change”, and make sure that oil has
been sealed with oil seal.
I4RS0A520001-01
(A)
1
I4RH01520003-01
IYSY01520005-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-13
Manual Transaxle Assembly ComponentsS7RS0B5206013
I6RS0C520005-01
1. Transaxle right case 24. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case : Apply sealant 99000-31260 to mating surface of left case and right
case. 25. 5th gear shift fork
3. Gear shift and select shaft assembly 26. Needle bearing
4. Transaxle left case plate 27. Input shaft 5th gear
5. Transaxle side cover : Apply sealant 99000-31260 to mating surface of side cover and left
case. 28. Reverse gear shift lever
6. Back up light switch 29. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring 30. Reverse gear shaft
8. Differential assembly 31. Washer
9. Oil level/filler plug : Apply sealant 99000-31260 to all around thread part of plug. 32. Reverse idler gear
10. Oil drain plug : Apply sealant 99000-31260 to all around thread part of plug. 33. Reverse shaft bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-35
6) Hold differential assembly with soft jawed vise (3),
install final gear (2) as shown in figure and then
tighten bolts (1) to specified torque.
CAUTION!
Use of any other bolts than specified ones is
prohibited.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS7RS0B5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Leve r and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A520043-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Transaxle oil drain plug 21 2.1 15.5 )
Transaxle oil level / filler plug 21 2.1 15.5 )
Back up light switch 23 2.3 17.0 )
Gear shift guide case bolt 23 2.3 17.0 )
Select lever bracket bolt 23 2.3 17.0 )
Gear shift interlock bolt 23 2.3 17.0 )
5th to reverse interlock guide bolt 23 2.3 17.0 )
Countershaft nut 100 10.0 72.5 )
Shift fork bolt 10 1.0 7.5 )
Side cover bolt 10 1.0 7.5 )
Reverse gear shift lever bolt 23 2.3 17.0 )
Reverse shaft bolt 23 2.3 17.0 )
Transaxle case bolt 23 2.3 17.0 )
Side bearing retainer bolt 23 2.3 17.0 )
Gear shift locating bolt 13 1.3 9.5 )
Left case plate bolt 23 2.3 17.0 )
Oil gutter bolt 10 1.0 7.5 )
Final gear bolt 90 9.0 65.0 )

Downloaded from www.Manualslib.com manuals search engine 7B-2 Air Conditioning System: Manual Type
Refrigerant Line
• Never use heat for bending pipes. When bending a pipe , try to make its bending angle as smooth as possible.
• Keep internal parts of air conditioning free from moistu re and dirt. When disconnecting any line from system, install
a blind plug or cap to the fitting immediately.
• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to O-ring.
• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
• Check local governmental regulations regarding working with refrigerator systems and its tooling.
• Route drain hose so that drained water does not make any contact to vehicle components.
• If pipes or hoses are replaced, replenish specified amount of compressor oil to compre ssor suction side referring to
“Replenishing Compressor Oil” in “Operation Procedure for Refrigerant Charge”.
Refrigerant Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-1 34a) into atmosphere would cause adverse effect to
environments.
NOTE
When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.

Refrigerant Charge
After performing compressor oil replenishment and evacuat ion, charge a proper amount of refrigerant to A/C system
referring to “Charge” in “Operation Procedure for Refrigerant Charge”.
3
1
2
4
5
I4RS0B720001-02
1. Suction hose : Apply compressor oil (refrigerant oil) to O-ring. 4. Expansion valve
: Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose : Apply compressor oil (refrigerant oil) to O-ring. 5. A/C refrigerant pressure sensor
: Apply compressor oil (refrigerant oil) to O-ring.
3. Liquid pipe : Apply compressor oil (refrigerant oil) to O-ring.