reverse SUZUKI SWIFT 2005 2.G Service Manual Online

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 Manual Transmission/Transaxle: 5B-21
c) Install differential side bearing shim to left case (4).
d) Apply oil to new O-ring of side bearing retainer (3), and install side bea ring retainer with new O-
ring to left case.
e) Tighten side bearing retainer bolts (1) to specified torque.
NOTE
Install side bearing retainer with its punch
mark (2) facing upward.

Tightening torque
Side bearing retainer bolt (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
10) Check locating springs (2, 4 and 5) for deterioration and replace with new one as necessary.
Locating spring
11) Install steel balls (3) and locating springs (2, 4 and 5) for respective gear shift shaft and tighten bolts (1) to
which sealant has been applied.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift locating bolt (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
12) Install new snap ring (1) using snap ring pliers (2).
13) To seat countershaft left bearing outer race (1) to bearing cone, and tap countershaft left bearing outer
race (1) using special tool and plastic hammer (2).
Special tool
(A): 09913–70123
Locating spring free
length
Standard Service limit
Low speed (2) 53.1 mm
(2.091 in.) 50.5 mm
(1.988 in.)
High speed (4) 45.9 mm
(1.807 in.) 44.0 mm
(1.732 in.)
5th & reverse (5) 29.9 mm
(1.777 in.) 28.5 mm
(1.122 in.)
1, (a)
2
4
3
I4RS0A520039-01
2. Input shaft 3. Input shaft left bearing
I2RH01520084-01
1
2
2
3
I6RS0C520012-01
I3RM0A520030-01

Downloaded from www.Manualslib.com manuals search engine 5B-22 Manual Transmission/Transaxle:
14) With putting a shim (2) on bearing outer race (3), place straightedge (1) over it and compress it by
hand through straightedge, and then measure
clearance “a” between case surface (4) and
straightedge using feeler gauge (5).
Clearance between case surface and
straightedge (Shim protrusion)
“a”: 0.08 – 0.12 mm (0.0032 – 0.0047 in.)
15) By repeating Step 14), select a suitable shim which adjusts clearance “a” to specification and put it on
bearing outer race.
NOTE
Insert 0.10 mm (0.0039 in.) feeler to know
whether or not a shim fulfills specification
quickly.

Available shim thickness
16) Place left case plate (2) inserting its end in groove of shift guide shaft (4) and tighten bolts (1) to which
thread lock cement has been applied.
NOTE
After tightening bolts, make sure that
countershaft (5) can be rotated by hand
feeling certain load.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
17) Install fifth gear referring to “Fifth Gear Disassembly and Assembly”.
18) Install gear shift and select shaft assembly referring to “Gear Shift and Select Shaft Assembly Removal
and Installation”.
19) Install back up light switch referring to “Back Up Light
Switch Removal and Installation”.
20) Check input shaft for rotation in each gear position.
21) Also confirm continuity of back up light switch in
reverse position using ohmmeter.
0.55 mm (0.021 in.) 0.90 mm (0.035 in.)
0.60 mm (0.023 in.) 0.95 mm (0.037 in.)
0.65 mm (0.025 in.) 1.00 mm (0.039 in.)
0.70 mm (0.027 in.) 1.05 mm (0.041 in.)
0.75 mm (0.029 in.) 1.10 mm (0.043 in.)
0.80 mm (0.031 in.) 1.15 mm (0.059 in.)
0.85 mm (0.033 in.)
I3RM0A520031-01
3. Input shaft
I4RS0A520042-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-31
Synchronizer Parts InspectionS7RS0B5206021
Check clearance “a” between synchronizer ring (2) and
gear (1), each chamfered tooth of gear, synchronizer
ring and sleeve, then determine parts replacement.
Clearance “a” between synchronizer ring and gear
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)Put the 2nd gear synchronizer outer ring (1), inner ring
(3) and the cone (2) together and then measure the step
difference between the outer ring and the inner ring. And
also check each chamfered tooth of gear and
synchronizer ring and replace with new one, if
necessary. Also, check gear tooth.
Difference “b” between synchronizer outer ring and
inner ring
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)
Gear Shift Shaft ComponentsS7RS0B5206022
I2RH01520048-01
I2RH01520059-01
5
3
4 6
1
2
8
7
77
(a)
(b)
(a)
(a)
I4RS0A520015-01
1. Low speed gear shift shaft
5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
2. High speed gear shift shaft 6. 5th gear shift fork : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
3. 5th & reverse gear shift shaft 7. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
4. 5th & reverse gear shift guide shaft 8. Shift fork bolt
: Apply thread lock 99000-32110 to bolt thread.

Downloaded from www.Manualslib.com manuals search engine 5B-32 Manual Transmission/Transaxle:
5th and Reverse Gear Shift Shafts Disassembly
and Assembly
S7RS0B5206023
Disassembly
Disassemble component parts using special tool and
hammer.
Special tool
(A): 09922–85811
Assembly
Replace or correct parts as required and assemble
shafts making sure that component parts are in proper
order as shown.
NOTE
• Distinguish reverse gear shift arm spring (Blue) (2) from low speed locating spring
(Yellow).
• Install 2 steel balls (3) in reverse gear shift arm (1) without fail.
• Drive in spring pin for reverse gear shift arm facing slit A toward 5th gear side.

Gear Shift Shaft and Fork InspectionS7RS0B5206024
Using feeler gauge, check clearance between fork (1)
and sleeve (2) and replace those parts if it exceeds limit.
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Service limit “a”: 1.0 mm (0.039 in.)
Insert each gear shift shaft into case and check that it
moves smoothly. If it doesn’t, correct using oilstone,
reamer or the like.
A: Face pin slit toward 5th gear side
4. Spring pin
5. 5th & reverse gear shift shaft
6. 5th & reverse gear shift yoke
7. 5th & reverse gear shift guide shaft
8. 5th gear side
I3RM0A520053-01
I2RH01520068-01

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 Clutch: 5C-3
Clutch Release Margin “C”1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) dep ressed, slightly push the
shift lever to re verse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by
“C” in figure.
Clutch release margin
“C”: 25 – 55 mm (0.98 – 2.17 in.)
6) If “C” is not within specificat ion, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”. Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS7RS0B5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to reservoir cap.
Air Bleeding of Clutch SystemS7RS0B5306003
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding
operation.
Brake Fluid
Refer to reservoir cap
2) Remove bleeder plug cap from clutch operating cylinder (3). Attach a vinyl tube (1) to bleeder plug
(4), and insert the other end into container (2).
2
1
“A”
3
2
1
3
“B”
“C”
4
5
I4RS0B530001-01
I4RS0A530023-01
3 4 1
2
3
I4RS0A530003-01

Downloaded from www.Manualslib.com manuals search engine 5C-6 Clutch:
Clutch Fluid Pipe Removal and InstallationS7RS0B5306007
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and push clamp (5) of clutch operating cylinder (4) and then
disconnect clutch fluid pipe (2).
Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted surface.
• Do not allow pipe to contact hard against vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and bleed air from system referring to “Clutch Pedal
Inspection” and “Air Blee ding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS7RS0B5306008
Check pipe (1) for dent, kink, crack, dirt and dust.
Replace if check result is not satisfactory.
Clutch Master Cylinder Removal and
Installation
S7RS0B5306009
Removal 1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe from clutch master cylinder (1) referring to “C lutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal.
5) Turn clutch master cylinder (1) clockwise as shown in figure, and then remove it.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
31
2
5
4
I4RS0B530003-01
3. Brake booster
1
I6RS0C530004-01
1
2
3
I4RS0B530005-01
“A”
I4RS0B530006-01