Transmission to engine SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-11
Gear Shift and Select Shaft Assembly ComponentsS7RS0B5206010
Gear Shift and Select Shaft Assembly Removal
and Installation
S7RS0B5206011
Removal1) Remove gear shift interlock bolt (1) and 5th to reverse interlock guide bolt (2) from transaxle case.
2) Remove gear shift & select shaft assembly (3). Installation
1) Apply grease to select lever shaft bush and select lever boss, and install gear shift and select shaft
assembly with new gasket into transaxle.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
2) Apply sealant to gear shift guide case bolts (1). Tighten gear shift guide case bolts to specified
torque.
B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift guide case bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
3) Tighten select lever brac ket bolt with select lever
bracket to specified torque.
Tightening torque
Select lever bracket bolt: 23 N·m (2.3 kgf-m, 17.0
lb-ft)
I6RS0C520010-01
1. Gear shift & select shaft 7. Gear shift guide case bolt
: Apply sealant 99000-31260 to bolt thread. 13. Select lever boss
: Apply grease 99000-25011 to internal and
external diameter.
2. 5th & reverse gear shift cam 8. Select lever bracket bolt : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Gear shift interlock plate 9. 5th to reverse interlock guide bolt
: Apply sealant 99000-31260 to bolt thread. : Do not reuse.
4. Gear shift & select lever 10. Gear shift interlock bolt
: Apply sealant 99000-31260 to bolt thread. : Apply transaxle oil.
5. Shift cable lever 11. Guide case
6. Select cable lever 12. Select lever shaft bush
: Apply grease 99000-25011 to whole area of bush.
3
12I4RS0A520024-01

Downloaded from www.Manualslib.com manuals search engine 5B-12 Manual Transmission/Transaxle:
4) Install washer and gear shift interlock bolt (2) to which sealant have been app lied and then tighten it
to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift interlock bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
5) Install washer and 5th to reverse interlock guide bolt (3) to which sealant have been applied and then
tighten it to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
5th to reverse interlock guide bolt (c): 23 N·m (
2.3 kgf-m, 17.0 lb-ft)
Gear Shift and Select Shaft Disassembly and
Assembly
S7RS0B5206012
1) Push pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and
specified spring pin removers as shown below.
Special tool
(A): 09922–85811 4.5 mm
(B): 09925–78210 6.0 mm
2) Inspect component parts for wear, distortion or
damage. If any detect is found, replace detective
part with new one.
NOTE
• Set new gear shift & select lever inner pin (8) and outer pin (9) facing each gap (“a”,
“b”) in the opposite direction as shown in
figure.
• When driving in pins, prevent shaft from being bent by supporting it with wood
block.
• Assemble 5th & reverse gear shift cam with its pit and pin aligned.
• Make sure to select an appropriate spring by identifying the painted colors to keep
gear shifting performance as designed.
– Low speed select spring – Light blue
– Reverse select spring – Yellow

“A” 1, (a), “B”
1, (a), “B” 2, (b), “B”
3, (c), “B”
I4RS0A520025-01
1. E-ring 10. Ball
2. Washer 11. Gear shift & select shaft
3. Reverse select spring 12. 5th & reverse gear shift cam
4. Gear shift interlock plate 13. 5th & reverse gear shift cam guide pin
5. Ball 14. Cam guide return spring
6. Gear shift interlock spring 15. 5th & reverse gear shift cam guide
7. Gear shift & select lever 16. Gear shift cam guide pin
8. Inner pin 17. Low speed select spring
9. Outer pin 18. Spring pin remover
I6RS0C520011-01

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 5B-14 Manual Transmission/Transaxle:
Fifth Gear Disassembly and AssemblyS7RS0B5206014
Disassembly1) Remove cover bolts and take off transaxle side cover (1).
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using snap ring pliers, remove circlip (1).
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchron izer levers, synchronizer
ring and input shaft 5th gear (5) all together. Use
gear puller for removal if spline fitting of hub is tight. 5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
11. Sensor cap 34. Washer
12. Oil gutter bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 35. Side bearing retainer
13. Left case plate bolts : Apply thread lock 99000-32110 to all around thread part of bolt. 36. O-ring
14. Sensor cap bolt 37. Oil seal
: Apply grease 99000-25011 to oil seal lip.
15. Side cover bolts 38. Outer race
16. Transaxle case bolts 39. Breather hose
17. 5th speed synchronizer ring 40. Side bearing retainer bolt
18. 5th speed synchronizer lever : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
19. 5th speed synchronizer sleeve & hub : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
20. Circlip :10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
21. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
22. Countershaft 5th gear : Do not reuse.
23. Countershaft nut : After tightening nut to specified torque, caulk nut securely. : Apply transaxle oil.
I4RS0A520027-01
342
1
5
I4RS0A520028-01
1(A)
2
I3RM0B521014-01
I4RS0A520041-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-15
Assembly1) Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and
synchronizer ring (4) as follows.
a) Install hub (1) to 5th speed synchronizer sleeves (2) in specified direction as shown in figure.
b) Fit 5th speed synchronizer levers (1) to hub (2) as shown in figure.
NOTE
Align protrusion A of 5th speed synchronizer
levers (1) with groove of hub (2).

c) Install synchronizer ring (1) to hub (2) as shown in figure.
2) Install 5th gear (1) to countershaft facing machined boss A inward.
3) Install needle bearing to input shaft, apply oil then install input shaft 5th gear (1) and special tool to stop
shaft rotation.
Special tool
(A): 09927–76060
4) Tighten new countershaft nut (2) to specified torque, and caulk countershaft nut securely.
Tightening torque
Countershaft nut (a): 100 N·m (10.0 kgf-m, 72.5
lb-ft)
A: Chamfered side B: Long boss
I4RH01520054-01
1
2
B
A
I4RH01520048-01
1A
2
A
I4RH01520049-01
A: Machined boss (Inside)
B: No machining (Outside)
1
2
I4RH01520055-01
I2RH01520088-01
1
(A)
2, (a)
I3RM0B521016-01

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
5) Fit 5th gear shift fork (1) to synchronizer sleeve (2) and hub (3) assembly and install them into input
shaft and gear shift shaft aligning punch mark (4)
with matching mark (5) on input shaft.
6) Tighten shift fork bolt (2) to which thread lock cement
has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
7) Using snap ring pliers, inst all new circlip (1) to input
shaft (3) in specified direction as shown in figure. 8) Clean mating surface of both left case (2) and side
cover (1), apply sealant to side cover (1) as shown in
figure by such amount t hat its section is 1.5 mm
(0.059 in.) in diameter, mate it with left case and then
tighten bolts to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Manual Transaxle Assembly Disassembly and
Reassembly
S7RS0B5206015
Disassembly
1) Remove gear shift and select shaft assembly referring to “Gear Shift an d Select Shaft Assembly
Removal and Installation”.
2) Remove fifth gear referring to “Fifth Gear Disassembly and Assembly”.
3) Remove left case plate.
4) Remove snap ring (1) using snap ring pliers (2).
4. Polished surface
I4RS0A520029-01
2, (a), “A”
1 33
4
1
I4RS0A520030-01
2. Input shaft 3. Input shaft left bearing
I4RS0A520031-01
1
2
2
3
I6RS0C520012-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-17
5) Remove gear shift locating bolts (1) with washers,
then take out locating springs and steel balls.
6) Remove back up light switch (2).
7) Remove reverse shaft bolt (2) with washer.
8) Remove case bolts (1) from outside and another bolts from clutch housing side.
9) Tapping left case flanges with plastic hammer, remove left case (3).
10) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3).
11) Remove reverse gear shift lever bolts (4) and reverse gear shift lever (5).
12) Pull out 5th & reverse gear shift guide shaft (6) together with 5th & reverse gear shift shaft (7). 13) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, then take out
input shaft assembly (1), countershaft assembly (2),
high speed gear shift shaft (3) and low speed gear
shift shaft (4) all at once.
14) Remove countershaft left bearing outer race from left case (1) using special tool.
Special tool
(A): 09913–70123
15) Remove side bearing retainer bolts.
16) Turn side bearing retainer (1) counterclockwise until it stops, and remove side bearing retainer using 2 flat
end rods (2) or the like.
17) Remove O-ring from side bearing retainer.
I2RH01520032-01
I4RS0A520032-01
I4RS0A520033-01
I2RH01520035-01
(A)
1
I4RH01520021-01
1
2
2
I4RS0A520034-01

Downloaded from www.Manualslib.com manuals search engine 5B-18 Manual Transmission/Transaxle:
18) Remove differential bearing shim.
19) Remove differential side bearing outer race from left case (1) using special tools.
Special tool
(A): 09924–74510
(B): 09926–27610
20) Remove differential gear assembly (1) from right case (2).
Reassembly 1) Install differential assembly (1) into right case (2). 2) Join input shaft assembly (5), countershaft assembly
(4), low speed gear shift shaft (2) and high speed
gear shift shaft (3) assemblies all together, then
install them into right case (1).
CAUTION!
Take care not to damage oil seal lip by input
shaft, or oil leakage may take place.

NOTE
• Input shaft right bearing on shaft can be
installed into right case tapping shaft with
plastic hammer.
• Check to make sure that countershaft is engaged with final g ear while installing.

3) Install 5th & reverse gear shift shaft (1) with 5th &
reverse gear shift guide shaft (2) into right case (5).
Reverse gear shift arm (4) has to be joined with
reverse gear shift lever (3) at the same time.
(A)
(B)
1
I4RS0A520035-01
I6RS0C520006-02
I6RS0C520006-02
I2RH01520080-01
I2RH01520081-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-19
4) Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) into case (4)
through idler gear and then align “A” in shaft with “B”
in case.
5) Fasten reverse gear shift lever bolts after applying thread lock cement.
: Thread lock cement 99000–32110 (Thread Lock
Cement Super 1322)
Tightening torque
Reverse gear shift lever bolt: 23 N·m (2.3 kgf-m,
17.0 lb-ft)
NOTE
• Make sure that washer (5) has been installed in shaft at above the gear.
• Check to confirm that reverse gear shift lever end has clearance “a” to idler gear
groove.

Distance between lever and idler gear shaft
“a”: 0.5 – 1.0 mm (0.02 – 0.04 in.) 6) Clean mating surfaces of both right and left cases,
apply sealant to right case (2) as shown in the figure
by such amount that its section is 1.5 mm (0.059 in.)
in diameter then mate it with left case (1).
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
7) Install reverse shaft bolt (4) to which thread lock cement has been applied, with aluminum washer
and tighten it to specified torque.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Reverse shaft bolt (c): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
8) Tighten case bolts (3) from outside tighten another case bolts from clutch housing side to specified
torque.
Tightening torque
Transaxle case bolt (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
I4RS0A520036-01
I3RM0A520043-01

Downloaded from www.Manualslib.com manuals search engine 5B-20 Manual Transmission/Transaxle:
9) Install side bearing retainer as follows.a) Install differential side bearing outer race to left case and then tap and accustom outer race
using special tool and plastic hammer.
CAUTION!
Do not drive in a race with hammer.
Driving it may cause to damage bearing.

Special tool
(A): 09926–27610
b) Select a shim of differential side bearing as follows.
i) Measure depth “a” from left case (1) face to side bearing outer race (2) using depth
gauge.
ii) Measure height “b” of side bearing retainer with depth gauge. iii) Calculate clearance a – b, and select
differential shim acco rding to the following
table.
Bearing shim specification
(A)
I4RH01520053-01
I4RS0A520037-01
“b”
I4RS0A520038-01
Clearance “a” – “b” Thickness of bearing
shim to be installed
0.636 – 0.665 mm
(0.0250 – 0.0261 in.) 0.75 mm (0.030 in.)
0.666 – 0.695 mm
(0.0262 – 0.0273 in.) 0.78 mm (0.031 in.)
0.696 – 0.725 mm
(0.0274 – 0.0285 in.) 0.81 mm (0.032 in.)
0.726 – 0.755 mm
(0.0286 – 0.0297 in.) 0.84 mm (0.033 in.)
0.756 – 0.785 mm
(0.0298 – 0.0309 in.) 0.87 mm (0.034 in.)
0.786 – 0.815 mm
(0.0310 – 0.0320 in.) 0.90 mm (0.035 in.)
0.816 – 0.845 mm
(0.0321 – 0.0332 in.) 0.93 mm (0.037 in.)
0.846 – 0.875 mm
(0.0333 – 0.0344 in.) 0.96 mm (0.038 in.)
0.876 – 0.905 mm
(0.0345 – 0.0356 in.) 0.99 mm (0.039 in.)
0.906 – 0.935 mm
(0.0357 – 0.0368 in.) 1.02 mm (0.040 in.)
0.936 – 0.965 mm
(0.0369 – 0.0379 in.) 1.05 mm (0.041 in.)
0.966 – 0.995 mm
(0.0380 – 0.0391 in.) 1.08 mm (0.043 in.)
0.996 – 1.025 mm
(0.0392 – 0.0403 in.) 1.11 mm (0.044 in.)
1.026 – 1.055 mm
(0.0404 – 0.0415 in.) 1.14 mm (0.045 in.)
1.056 – 1.085 mm
(0.0416 – 0.0427 in.) 1.17 mm (0.046 in.)
1.086 – 1.115 mm
(0.0428 – 0.0438 in.) 1.20 mm (0.047 in.)
1.116 – 1.145 mm
(0.0439 – 0.0450 in.) 1.23 mm (0.048 in.)
1.146 – 1.175 mm
(0.0451 – 0.0462 in.) 1.26 mm (0.050 in.)
1.176 – 1.205 mm
(0.0463 – 0.0474 in.) 1.29 mm (0.051 in.)
1.206 – 1.235 mm
(0.0475 – 0.0486 in.) 1.32 mm (0.052 in.)
1.236 – 1.265 mm
(0.0487 – 0.0498 in.) 1.35 mm (0.053 in.)
1.266 – 1.295 mm
(0.0499 – 0.0509 in.) 1.38 mm (0.054 in.)
1.296 – 1.325 mm
(0.0510 – 0.0521 in.) 1.41 mm (0.056 in.)