torque specification SUZUKI SWIFT 2005 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-149
Countershaft bearing preload1) After applying A/T fluid to countershaft assembly (1) and differential assembly (2), fit them.
2) Install torque converter housing to transaxle case, then tighten bolts to specified torque.
Tightening torque
Torque converter housing bolt: 29 N·m (2.9 kgf-
m, 21 lb-ft)
3) Measure bearing preload (b) by using special tool. Special tool
(A): 09928–06050
Countershaft bearing preload (b) measured as
starting torque
In the case of new bearing: 0.33 – 0.96 N⋅ m (3.3 –
9.8 kg-cm, 0.24 – 0.69 lb-ft)
In the case of reused bearing: 0.17 – 0.38 N ⋅m
(1.7 – 3.8 kg-cm, 0.12 – 0.28 lb-ft) 4) If bearing preload is out of specification, select shim
with suitable thickness from among the list below
and replace it. Then adjust countershaft bearing
preload within specification.
Available shim thickness
5) Remove differential assembly and countershaft assembly.
Countershaft bearing
preload =(b) – Differential side bearing
preload (a)
I2RH0B510257-01
I3RM0B510067-01
Thickness Identification mark
1.70 (0.066 in.) 1
1.75 (0.068 in.) 2
1.80 (0.070 in.) 3
1.85 (0.072 in.) 4
1.90 (0.074 in.) 5
1.93 (0.075 in.) 6
1.96 (0.077 in.) 7
1.99 (0.078 in.) A
2.02 (0.079 in.) B
2.05 (0.080 in.) C
2.08 (0.081 in.) D
2.11 (0.083 in.) E
2.14 (0.084 in.) F
2.17 (0.085 in.) G
2.20 (0.086 in.) H
2.25 (0.088 in.) K
2.30 (0.090 in.) L
2.35 (0.092 in.) M
2.40 (0.094 in.) N
2.45 (0.096 in.) P
2.50 (0.098 in.) Q
2.55 (0.100 in.) R
2.60 (0.102 in.) S
2.65 (0.104 in.) U
2.70 (0.106 in.) W

Downloaded from www.Manualslib.com manuals search engine 5A-150 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS7RS0B5106060
CAUTION!
• Automatic transaxle consists of highly precise parts. As even flaw in small part
may cause oil leakage or decrease in
function, check each part carefully before
installation.
• Clean all parts with compressed air. Never use wiping cloths or rags.
• Before assembling new clutch or brake discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before
assembly.
• Use Suzuki Super Grease “C” to retain parts in place.
• Be sure to install thrust bearings and races in correct direction and position.
• Make sure that snap ring ends are not aligned with one of cut outs and are
installed in groove correctly.
• Do not use adhesive cements on gaskets and similar parts.
• Be sure to torque each bolt and nut to specification.

1) Install new manual shift sh aft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.5 – 1.5 mm (0.02 – 0.06 in.) 2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl ro d (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using spring pin remover with 3.5 mm (0.14 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
I2RH0B510258-01
I2RH0B510259-01
I2RH0B510260-01
I2RH0B510261-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-153
16) Install new planetary ring gear subassembly (1) to reduction drive gear (3) by using special tools and
hydraulic press.
CAUTION!
• Do not reuse planetary ring gear subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.
• Do not use transaxle case as groundwork to press fit planetary ring gear
subassembly.
• Do not give load more than 20 kN (2000 kg, 4410 lb) with hydraulic press. Otherwise, it
may result in damaging reduction drive
gear bearing.

Special tool
(A): 09951–18210
(B): 09944–78210 17) Using a small torque
wrench, while turning to
counter drive gear 100 rpm and measure the
preload.
CAUTION!
• Do not tighten nut over the specifications so that reduction drive gear nut would not
be broken.
• Carry out this procedure on rubber mat in order not to damage transaxle case.

Reduction drive gear bearing preload measured
as starting torque
Standard: 0.05 – 0.35 N ⋅m (0.5 – 3.5 kg-cm, 0.036
– 0.253 lb-ft)
18) Caulk reduction drive gear nut (1).
19) Apply A/T fluid to planetary gear assembly (1), then fit it to planetary ring gear assembly.
2. Stand that can slightly lift transaxle case.
I2RH0B510272-01
I2RH0B510273-01
I2RH0B510274-01
1
I2RH0B510275-01

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 Automatic Transmission/Transaxle: 5A-161
60) Measure input shaft thrust play.Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
When input shaft thrust play is out of specification,
select input shaft front th rust bearing with proper
thickness from among the following table and
replace it.
Available input shaft front thrust bearing
thickness
61) After applying A/T fluid to new O-ring, fit it to breather union (2). Then install breather union to
transaxle case.
62) Install breather hose (1). 63) Wipe off and clean mating surface between
transaxle case (1) and torque converter housing.
64) Apply sealant to torque converter housing by using a nozzle (2) as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
65) Install torque converter housing to transaxle case, tighten bolts to specified torque.
CAUTION!
Apply sealant to threads of four bolts shown
in figure before tightening.

“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Tightening torque
Torque converter housing bolt (a): 29 N·m (2.9
kgf-m, 21 lb-ft)
Thickness
Outside
diameter Inside diameter
3.45 mm
(0.14 in.) 48.5 mm
(1.90 in.) 32.9 mm
(1.30 in.)
4.05 mm
(0.16 in.) 48.5 mm
(1.90 in.) 32.5 mm
(1.28 in.)
I2RH0B510313-01
I2RH0B510314-01
1 2
“A”
I2RH0B510315-01
I3RM0B510069-01

Downloaded from www.Manualslib.com manuals search engine 5A-164 Automatic Transmission/Transaxle:
74) Connect solenoid connectors to solenoid valves identifying their installing positions by wire colors,
and install transmission fluid temperature sensor to
its clamp.
Solenoid valve coupler specification
75) Install oil strainer assembly (1).
Tightening torque
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) 76) Install oil cleaner magnets (1) in oil pan (2).
NOTE
If metal particles are attached to the magnets,
clean them before installing.

77) Install new oil pan gasket (1) between transaxle case
and oil pan (2).
78) Tighten oil pan bolts to specified torque diagonally and little by little.
Tightening torque
Oil pan bolt (a): 7.0 N·m (0.7 kgf-m, 5.0 lb-ft)
79) After applying A/T fluid to new O-rings, fit it to fluid inlet union (1). Then inst all fluid outlet union to
transaxle case.
Tightening torque
Fluid outlet union (a): 25 N·m (2.5 kgf-m, 18.0 lb-
ft)
80) Install new gaskets (2) and then install fluid cooler pipes.
Tightening torque
Fluid cooler pipe union bolt (b): 22 N·m (2.2 kgf-
m, 16.0 lb-ft)
Fluid cooler pipe bracket bolt (c): 10 N·m (1.0
kgf-m, 7.5 lb-ft)
Solenoid valve coupler Wire color
Shift solenoid valve-A (No.1) (2) White
Shift solenoid val ve-B (No.2) (3) Black
Timing solenoid valve (1) Yellow
TCC pressure control solenoid
valve (4) Light green /
Brown
Pressure control solenoid valve (5) Gray / Green
Transmission fluid temperature
sensor (6) Orange
12
3 5
4
6
I4RS0A510030-01
I2RH0B510325-01
I2RH0B510326-01
I2RH0B510327-01

Downloaded from www.Manualslib.com manuals search engine 5A-166 Automatic Transmission/Transaxle:
91) Bend dents of lock washer (1) in order to prevent displacement of lock washer.
92) Install manual select lever (1). Tightening torque
Manual select lever nut (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
93) Install engine mounting LH bracket (1). Tightening torque
Engine mounting LH bracket bolt (a): 55 N·m (
5.5 kgf-m, 40.0 lb-ft) 94) Install torque converter (3) noting the following
points.
CAUTION!
• Before installing converter, make sure that its pump hub portion is free from nicks,
burrs or damage which may cause oil seal
to leak.
• Be very careful not to drop converter on oil pump gear. Damage in gear, should it
occur, may cause a critical trouble.

• Install torque converter aligning grooves (1) of torque converter and projection (2) of oil pump
drive gear.
• Install torque converter, using care not to damage oil seal of oil pump.
• After installing torque converter, check that distance “a” is within specification.
Torque converter installing position
“a”: More than 19.9 mm (0.783 in.)
• Check torque converter for smooth rotation.
• Apply grease around cup (6) at the center of torque converter.
“C”: Grease 99000–25011 (SUZUKI Super
Grease A)
1
I3RM0B510075-01
1
(a)
I3RM0B510076-01
I3RM0B510077-01
4. Flange nut 5. Torque converter housing
I2RH0B510337-01

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 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