Manual transmission SUZUKI SWIFT 2005 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 5B-2 Manual Transmission/Transaxle:
I6RS0C520009-01
1. 5th speed sleeve & hub8. Reverse idler gear15. Countershaft 3rd gear
2. Input shaft 5th gear 9. Input shaft16. Countershaft 2nd gear
3. Input shaft 4th gear 10. Right case17. Low speed synchronizer sleeve & hub
4. High speed synchronizer sleeve & hub 11. Side cover 18. Countershaft 1st gear
5. Input shaft 3rd gear 12. Countershaft 5th gear19. Final gear
6. Left case 13. Countershaft 4th gear20. Differential case
7. Reverse gear shaft 14. Countershaft

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-5
Gear Shift Control Lever and Cable ComponentsS7RS0B5206003
1
3
4
(a)
7
A
(b)5
A
111 2
10
(c)
9
6
8 2
I7RS0A521001-03
1. Gear shift control lever knob 9. Cable bracket
2. Cable bracket bolt 10. Clip
Be sure to direct claw of clip to M/T side as shown in figure.
3. Gear shift lever boot 11. To gear shift control lever assembly
4. Gear shift control cable : Apply grease 99000-25011 to cable end. 12. To M/T
5. Gear select control cable : Apply grease 99000-25011 to cable end. : 13 N
⋅m (1.3 kgf-m, 9.5 lb-ft)
6. Gear shift control lever assembly mounting nut : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
7. Gear shift control lever assembly : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
8. Cable grommet bolt : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 5B-6 Manual Transmission/Transaxle:
Gear Shift Control Lever and Cable Removal
and Installation
S7RS0B5206004
Removal1) Remove console box.
2) Disconnect cable ends (4) from pivot (5) of gear shift control lever assembly.
3) Disconnect gear shift and select control cables (1) from gear shift control lever assembly (2) while
pressing claw (6) as shown in figure.
4) Remove gear shift control lever assembly mounting nuts (3) and gear shift lever assembly from floor
panel.
5) Disconnect gear shift and select control cables from transaxle referring to step 2) to step 5) of
“Dismounting” under “Manual Transaxle Unit
Dismounting and Remounting”.
6) Remove cable grommet bolt, and then remove gear shift and select control cables from floor panel.
Installation
Reverse removal procedure for installation nothing the
following.
• Tighten each bolts and nuts to specified torque referring to “Gear Shift Control Lever and Cable
Components”.
• Adjust gear select control cable referring to “Gear Select Control Cable Adjustment”.
Gear Select Control Cable AdjustmentS7RS0B5206005
1) Release lock plate (1) which restricts moving of cable end holder (2).
2) Push cable end holder (2) out from adjuster (4) using appropriate tool (3) to disengage cable.
35
4
2
31
6
I7RS0A521002-01I4RS0A520004-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-7
3) Apply grease to pin (5) of gear shift control lever, and then install adjuster (1) into pin of gear shift control
lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in the direction of A.
NOTE
At this time, do not a pply force in the cable
operation direction B to adjuster.

5) Slide lock plate (3) in the direction of C, until it gets over the claw (4) of cable end holder.
Back Up Light Switch Removal and InstallationS7RS0B5206006
Removal
1) Remove battery and tray with coolant reservoir.
2) Disconnect back up light switch coupler (1).
3) Remove back up light switch (2).
Installation 1) Apply oil to new O-ring (1) and tighten back up light switch (2) to specified torque.
Tightening torque
Back up light switch (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
2) Connect back up light switch coupler.
3) Install battery and tray, and then install coolant reservoir to battery tray.
Back Up Light Switch InspectionS7RS0B5206007
Check back up light switch for function using ohmmeter.
Back up light switch specification
Switch ON (Push): Continuity
Switch OFF (Release ): No continuity
3
3
41
2
A
C
1
B
5, “A”
I4RS0A520005-01
3. Gear shift and select shaft assembly
3
1
2
I4RS0A520010-01
1 2, (a)
I3RH0A520006-01
I4RS0A520011-01

Downloaded from www.Manualslib.com manuals search engine 5B-8 Manual Transmission/Transaxle:
Manual Transaxle Unit ComponentsS7RS0B5206008
13
6(a)
5
14(c)
114 7
(b)
12
7(b)
8
2
5 [A]
1
10
6
(a)
(a)
(b)3
9
9
(b)
(d)
I6RS0C520004-03
[A]: Forward
7. Engine left mounting bracket bolt and nuts 14. Clutch operating cylinder bolt
1. Engine 8. Clutch housing lower plate : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
2. Transaxle 9. Engine rear mounting bracket bolts : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
3. Engine rear mounting and bracket 10. Transaxle to engine nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Back up light switch connector 11. Ground cable : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
5. Clutch operating cylinder 12. Engine left mounting bracket
6. Transaxle to engine bolt 13. Gear shift & select control cables

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Manual Transaxle Unit Dismounting and
Remounting
S7RS0B5206009
Dismounting1) Drain coolant and transaxle oil.
2) Remove coolant reservoir with reservoir hose.
3) Remove battery and tray.
4) Remove air cleaner case and resonator.
5) Disconnect gear shift and gear select control cables (1) while pressing claws (2) of clip (3).
6) Disconnect back up light switch coupler and undo wiring harness clamps.
7) Remove ground cable from transaxle.
8) Remove clutch operating cylinder with fluid hose from transaxle.
9) Remove water inlet No.2 pipe from transaxle.
10) Remove starting motor re ferring to “Starting Motor
Dismounting and Remounting in Section 1I”.
11) Remove transaxle to engine bolts (1) of upper side. 12) Support engine using supporting device (1).
CAUTION!
Do not apply supporting device to projection
part A. If do so, it may be deformed.

13) Remove front drive shafts and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
14) Remove exhaust No.2 pipe referring to “Exhaust Pipe and Muffler Removal a nd Installation in Section
1K”.
15) Remove clutch housing lower plate (1).
1
2
3
I7RS0A521003-01
1
1
I4RS0A520018-01
1
A
I4RS0A520019-01
1I4RS0A520020-01

Downloaded from www.Manualslib.com manuals search engine 5B-10 Manual Transmission/Transaxle:
16) Remove engine under covers.
17) Support transaxle with transmission jack.
18) Remove transaxle to engine bolts and nut of lower side.
19) Remove engine left mounting (1) with bracket (2).
20) Remove engine rear mounting bracket bolts (1).
21) Remove other attached parts from transaxle, if any.
22) Pull transaxle so as to disconnect input shaft from clutch disc, and then lower it. Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer when installing it into differential gear.

Reverse dismounting procedure for remounting noting
the following.
• Tighten each bolts and nuts to specified torque referring to “Manual Transaxle Unit Components”.
• Set each clamp for wiring securely.
• Fill transaxle oil referring to “Manual Transaxle Oil
Change”.
• Fill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
• Install hook (1) and ground cable (2) at specified position as shown in figure.
• Connect battery and check function of engine, clutch
and transaxle.
1
2
I4RS0A520021-01
1
I4RS0A520022-01
3. Transaxle side cover 4. Transaxle left case
90
1
2 3
4
I4RS0A520023-01