forward SUZUKI SWIFT 2005 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-115
35) Remove 2nd brake gasket (1).
36) Measure O/D and 2nd coast brake piston stroke.If piston stroke exceeds specification, inspect and
replace plates and discs.
• Measure dimension “a” from mating surface of transaxle case to O/D and 2nd coast brake rear
plate (1) using straightedge and micrometer
caliper.
• Measure dimension “b” from O/D and 2nd coast brake piston (2) to rear cover assembly mating
surface using straightedge and micrometer
caliper.
• Calculate piston stroke from measured value of dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.) 37) Remove forward and reverse clutch assembly (1).
38) Remove intermediate shaft thrust bearing front race
(1), thrust bearing (2) and rear race (3) from forward
and reverse clutch assembly (4).
NOTE
If intermediate shaft thrust bearing and/or
races are not found on forward and reverse
clutch assembly, they may have been left in
transaxle.

39) Remove O/D and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4).
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Downloaded from www.Manualslib.com manuals search engine 5A-116 Automatic Transmission/Transaxle:
40) Remove forward clutch hub (1).
41) Remove rear sun gear thrust bearing (1) from forward clutch hub (2).
NOTE
If rear sun gear thrust bearing is not found on
forward clutch hub, it may have been left in
transaxle.

42) Remove rear sun gear thrust bearing race (1). 43) Remove rear planetary sun gear subassembly (1)
and one-way clutch No.1 assembly (2).
44) Remove planetary gear thrust bearing (1).
NOTE
If planetary gear thrust bearing is not found
on one-way clutch No.1 assembly, it may
have been left in transaxle.

45) Remove one-way clutch No.1 assembly (2) from rear planetary sun gear subassembly (3).
46) Remove planetary carrier thrust washer (1).
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Downloaded from www.Manualslib.com manuals search engine 5A-128 Automatic Transmission/Transaxle:
Forward and Reverse Clutch Assembly ComponentsS7RS0B5106041
I3RM0B510061-01
1. Forward clutch balancer8. Intermediate shaft seal ring15. Forward clutch retaining plate
2. Forward clutch return spring subassembly 9. Reverse clutch plate snap ring 16. Forward clutch disc
3. Forward clutch piston 10. Reverse clutch retaining plate 17. Forward clutch separator plate
4. Forward clutch piston O-ring 11. Reverse clutch separator plate 18. Balancer snap ring
5. Forward clutch drum 12. Reverse clutch disc : Apply automatic transaxle fluid.
6. Forward clutch drum O-ring 13. Reverse clutch cushion plate : Do not reuse.
7. Intermediate shaft subassembly 14. Forward clutch plate snap ring

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-129
Forward and Reverse Clutch Assembly
Preliminary Check
S7RS0B5106042
1) Install forward and reverse clutch assembly (1) to
transaxle rear cover (2), blow in compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) through oil
hole (4) of transaxle rear cover with the special tool
attached on the upper surf ace of reverse clutch
retaining plate (3), and measure reverse clutch
piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) through oil hole (1) of transaxle rear
cover with the special tool attached on the upper
surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Forward and Reverse Clutch Assembly
Disassembly and Reassembly
S7RS0B5106043
Disassembly
1) Remove reverse clutch plate snap ring (1) and take out reverse clutch retaini ng plate, discs, separator
plates and clutch cushion plate from intermediate
shaft subassembly.
2) Remove forward clutch plate snap ring (1) and take out forward clutch retaining plate, discs and
separator plates from forward clutch drum.
3) Remove balancer snap ring by using special tool and hydraulic press.
Special tool
(A): 09926–97610
CAUTION!
Do not press forward clutch return spring
subassembly in over 1.5 mm (0.059 in.).
Excessive compression may cause damage
to return spring subassembly and/or
balancer.

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Downloaded from www.Manualslib.com manuals search engine 5A-130 Automatic Transmission/Transaxle:
4) Remove forward clutch balancer (1).
5) Remove forward clutch return spring subassembly
(1).
6) Install intermed iate shaft subassembly (1) to
transaxle rear cover (2). Apply compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) to oil hole (3)
of transaxle rear cover to remove forward clutch
piston (4). 7) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of transaxle rear cover to
remove forward clutch drum (2).
8) Remove forward clutch piston O-ring (1) from intermediate shaft subassembly (2).
9) Remove forward clutch drum O-ring (1) from forward clutch drum (2).
10) Remove intermediate shaft seal ring (1) from intermediate shaft subassembly (2).
2. Intermediate shaft subassembly
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-131
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Before assembling, apply automatic transaxle fluid to component parts.
• Replace O-rings and seal ring with new ones.
• Do not damage forward clutch return spring subassembly and balancer (1) by pressing forward
clutch return spring subassembly passing through its
original installing position over 1.5 mm (0.059 in.).
Special tool
(A): 09926–97610
• Apply A/T fluid to forward clutch separator plates (1), discs (2) and retaining plate (3).
• Install forward clutch separator plates (1), discs (2) and retaining plate (3), then snap ring (4) to forward
clutch drum. • Install forward clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
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4
1
2 3
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[A]: Correct
[B]: Incorrect
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Downloaded from www.Manualslib.com manuals search engine 5A-132 Automatic Transmission/Transaxle:
• Measure forward clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
forward clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Available forward clutch retaining plate thickness
• Install reverse clutch cushion plate (1) in correct direction as shown in figure.
• Apply A/T fluid to reverse clutch cushion plate (1),
reverse clutch separator plate (2), discs (3) and
retaining plate (4).
• Install reverse clutch cushio n plate (1), reverse clutch
separator plate (2), discs (3), retaining plate (4) and
then snap ring (5) to inte rmediate shaft subassembly. • Install reverse clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
• Measure reverse clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
reverse clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
Available reverse clutch retaining plate thickness
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.1 mm (0.122 in.) 5
3.2 mm (0.126 in.) 2
3.3 mm (0.130 in.) 6
3.4 mm (0.134 in.) 3
3.5 mm (0.138 in.) 7
3.6 mm (0.142 in.) 4
1. Oil hole
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[A]: Correct[B]: Incorrect
ThicknessIdentification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
3.6 mm (0.142 in.) 4
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-133
Forward and Reverse Clutch Assembly
Inspection
S7RS0B5106044
Clutch, Discs, Separator Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
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.

Forward Clutch Return Spring Subassembly
Measure free length of fo rward clutch return spring.
Forward clutch return spring free length
24.04 mm (0.946 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Forward Clutch Piston Lip and Forward Clutch
Balancer Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
Forward Clutch Drum Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
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Downloaded from www.Manualslib.com manuals search engine 5A-156 Automatic Transmission/Transaxle:
32) Apply A/T fluid to one-way clutch No.1 assembly (3) and install one-way clutch No .1 assembly (3) to rear
planetary sun gear subassembly (2).
33) Apply A/T fluid to planetary gear thrust bearing (1), then install it to one-way clutch No.1 assembly (3).
34) After applying A/T fluid to rear planetary sun gear subassembly and one-way clutch No.1 assembly (1),
install them in transaxle case (2). 35) After applying A/T fluid to rear sun gear thrust
bearing race (1), install it to rear planetary sun gear
(2).
36) After applying A/T fluid to rear sun gear thrust bearing (1), install it to forward clutch hub (2).
37) After applying A/T fluid to forward clutch hub (1), install it in transaxle case (2).
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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.)
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“a”
“a”
1 2
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