Clutch pressure SUZUKI SWIFT 2006 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 5A-40 Automatic Transmission/Transaxle:
Trouble Diagnosis 3
Off-vehicle repairNon operate TCC (lock-
up) system
Malfunction of TCC solenoid valve
Inspect. If NG, replace.
Malfunction of shift solenoid valve-A
and/or -B Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of input shaft speed sensor Inspect. If NG, replace.
Malfunction of transmission range
sensor Inspect. If NG, replace.
Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve Inspect. If NG, replace valve body assembly.
Malfunction of throttle position sensor Inspect referring to “Electric Throttle Body
Assembly On-Vehicle Inspection in Section
1C”. If NG, replace.
Malfunction of engine coolant
temperature sensor Inspect referring to “ECT Sensor Inspection in
Section 1C”. If NG, replace.
Malfunction of brake light switch Inspect referring to “Brake Light Switch
Inspection in Section 9B”. If NG, replace.
Faulty valve body component Replace valve body assembly.
Excessive “N”
→ “D” or
“N”
→ “R” time lag Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Pressure control solenoid valve circuit
faulty Inspect. If NG, replace valve body assembly.
Clogged oil strainer Replace.
Faulty valve body component Replace valve body assembly.
Condition Possible cause Correction / Reference Item
Condition
Possible cause Correction / Reference Item
Unable to run in all range Faulty oil pump Inspect. If NG, replace.
Seized or broken planetary gear Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Damaged drive plate Inspect. If NG, replace.
Faulty forward clutch Inspect. If NG, replace.
Faulty reverse clutch Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Faulty torque converter Replace.
Excessive “N”
→ “D” shift
shock Faulty forward clutch
Inspect. If NG, replace.
Excessive “N”
→ “R” shift
shock Faulty reverse clutch
Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Poor 1
→ 2 shift,
excessive shock or
slippage Faulty 2nd brake
Inspect. If NG, replace.
Faulty one-way No.1 clutch Inspect. If NG, replace.
Poor 2
→ 3 shift,
excessive shock or
slippage Faulty direct clutch
Inspect. If NG, replace.
Poor 3
↔ O/D shift,
excessive shock or
slippage Faulty forward clutch
Inspect. If NG, replace.
Faulty O/D and 2nd coast brake Inspect. If NG, replace.
Poor 3
→ 2 shift,
excessive shock or
slippage Faulty direct clutch
Inspect. If NG, replace.
Faulty one-way No.1 clutch Inspect. If NG, replace.
Poor 2
→ 1 shift,
excessive shock or
slippage Faulty 2nd brake
Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-41
No Gear Shift to 4th gearS7RS0B5104019
System Description
TCM does not shift to 4th gear under any of the following condition.
• “3” position switch is turned ON.
• Engine coolant temperature is less than 50 °C (122 °F).
• A/T fluid temperature is less than 20 °C (68 °F).
• A/T fluid temperature is more than 130 °C (266 °F) while TCM is detecting P2762, P2763 and P2764.
• TCM detects the following DTCs. P0712 / P0713 / P0717 / P0722 / P0787 / P0788 / P0961 / P0962 / P0963 / P0973 / P0974 / P0976 / P0977 / P1702
/ P1703 / P1774 / P1777
Troubleshooting
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

Non operate TCC (lock-
up) system Faulty torque converter
Replace.
Excessive “N”
→ “D” time
lag Faulty oil pump
Inspect. If NG, replace.
Faulty forward clutch Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Leakage from “D” range fluid pressure
circuit Replace valve body assembly.
Excessive “N”
→ “R” time
lag Faulty oil pump
Inspect. If NG, replace.
Faulty reverse clutch Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
Poor engine brake in
downshift to “2” range Faulty O/D and 2nd coast brake
Inspect. If NG, replace.
Poor engine brake in
downshift to “L” range Faulty 1st and reverse brake
Inspect. If NG, replace.
Condition Possible cause Correction / Reference Item
Step
Action YesNo
1 Was “A/T System Check” performed? Go to Step 2.Go to “A/T System
Check”.
2 Check DTC
Is DTC P0712, P0713, P0717, P0722, P0961, P0962,
P0963, P0973, P0974, P0976, P0977, P1702, P1703,
P1774 and/or P1777 detected? Go to applicable DTC
diag. flow.
Go to Step 3.

Downloaded from www.Manualslib.com manuals search engine 5A-76 Automatic Transmission/Transaxle:
DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range /
Performance
S7RS0B5104050
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) Connect scan tool to DLC with ignition switch turned OFF.
2) Clear DTC in TCM memory.
3) Start engine.
4) Keep engine running at idle speed for 30 seconds or more.
5) Stop vehicle and check DTC.
12V
C34-5
C34-3
WHT/BLU
WHT/BLK
3
1
2
53
C34C35
[A]
I4RS0A510019-01
1. TCM
3. A/T
2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side)
DTC detecting conditionTrouble area
Difference between target current of TCC solenoid valve
circuit and monitor current of TCC solenoid valve circuit is
more than specification. • TCC solenoid valve or its circuit malfunction
•TCM

Downloaded from www.Manualslib.com manuals search engine 5A-78 Automatic Transmission/Transaxle:
DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit HighS7RS0B5104043
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

1) Connect scan tool to DLC with ig nition switch OFF, if available.
2) Clear DTC in TCM memory.
3) Start engine.
4) Keep engine running at idle speed in “P” range for 10 seconds or more.
5) Check DTC.
DTC Troubleshooting
1. TCM 3. A/T
2. TCC lock-up pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side)
DTC detecting conditionTrouble area
Voltage of TCC lock-up pressure control solenoid valve TCM
terminal is high although TCM is commanding TCC lock-up
pressure control sole noid to turn OFF. • TCC lock-up pressure contro
l solenoid valve circuit
shorted to ground
• Malfunction of TCC lock-up pressure control solenoid valve
•TCM
12V
C34-5
C34-3
WHT/BLU
WHT/BLK
3
1
2
53
C34C35
[A]
I4RS0A510019-01
Step
Action YesNo
1 Was “A/T System Check” performed? Go to Step 2.Go to “A/T System
Check”.

Downloaded from www.Manualslib.com manuals search engine 5A-80 Automatic Transmission/Transaxle:
DTC P2764: Torque Converter Clutch Circuit Pressure Control Solenoid Control Circuit LowS7RS0B5104044
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

1) Connect scan tool to DLC with ig nition switch OFF, if available.
2) Clear DTC in TCM memory.
3) Start engine.
4) Keep engine running at idle speed in “P” range for 20 seconds or more.
5) Check DTC.
DTC Troubleshooting
1. TCM 3. A/T
2. TCC pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side)
DTC detecting condition Trouble area
Voltage of TCC lock-up pressure control solenoid valve TCM
terminal is low although TCM is commanding TCC lock-up
pressure control sole noid to turn ON. • TCC lock-up pressure contro
l solenoid valve circuit
shorted to ground
• Malfunction of TCC lock-up pressure control solenoid valve
•TCM
12V
C34-5
C34-3
WHT/BLU
WHT/BLK
3
1
2
53
C34C35
[A]
I4RS0A510019-01
Step
Action YesNo
1 Was “A/T System Check” performed? Go to Step 2.Go to “A/T System
Check”.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-83
Connector “C34”Terminal Wire color Circuit Standard
voltage Condition
1 BLK Ground 0 – 1 V Ignition switch ON
2 LT GRN/
BLK Pressure control
solenoid valve (–)
0.6 – 1.0 V Ignition switch ON
3WHT/BLK TCC pressure control
solenoid valve (–) 0.6 – 1.0 V Ignition switch ON
4GRY Pressure control
solenoid valve (+) *0 – 0.6 V
↑↓
10 – 14 V
(“Reference waveform No. 1: ”) Engine running at idling.
(Output signal is duty pulse. Duty ratio varies
depending on throttle valve opening.)
5WHT/BLU TCC pressure control
solenoid valve (+) *0 – 0.6 V
↑↓
10 – 14 V
(“Reference waveform No. 2: ”) Engine running at idling.
(Output signal is duty pulse. Duty ratio varies
depending on torque converter clutch operating
condition.)
6 YEL/BLK Power source 10 – 14 V Ignition switch ON
7WHT CAN communication
line (Low) *2.5 – 3.6 V
↑↓
1.6 – 2.5 V
(“Reference waveform No. 3: ”) Engine running at idling with after warming up.
(CAN communication signal is pulse. Pulse signal
frequency varies depending on engine condition.))
8— — — —
9— — — —
10 — —— —
11 LT G R N Transmission fluid
temperature sensor (+) 2.9 – 3.1 V Ignition switch ON, fluid temperature is 20
°C (68 °F)
0.3 – 0.5 V Ignition switch ON, fluid temperature is 100 °C (212 °F)
12 ORN Transmission fluid
temperature sensor (–) 0 – 1 V Ignition switch ON
13 — —— —
14 BLU/BLK Timing solenoid valv e 0 – 1 V Ignition switch ON
15 BLK/YEL Shift solenoid valve-B
(No.2) 9 – 14 V Ignition switch ON, select lever in “P” range
16 BRN Shift solenoid valve-A
(No.1) 9 – 14 V Ignition switch ON, select lever in “P” range
17 RED CAN communication
line (High) *2.5 – 3.6 V
↑↓
1.6 – 2.5 V
(“Reference waveform No. 3: ”) Engine running at idling with after warming up.
(CAN communication signal is pulse. Pulse signal
frequency varies depending on engine condition.)
18 — —— —
19 — —— —
20 — —— —
21 — —— —
22 — —— —
23 BLK Ground 0 – 1 V Ignition switch ON
24 WHT/RED Power source
for back-
up 10 – 14 V Constantly

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-127
Direct Clutch Assembly InspectionS7RS0B5106040
Clutch Discs, 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, discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Direct Clutch Return Spring Subassembly
Measure free length of direct clutch return spring.
Direct clutch return spring free length
“a”: 36.04 mm (1.419 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Direct Clutch Piston
Shake direct clutch piston lightly and check that check
ball (1) is not stuck.
Blow in low pressure air (Max. 100 kPa, 1 kg/cm
2, 15 psi)
to check ball to check that there is no leakage.
I2RH0B510172-01
I2RH0B510173-01
I2RH0B510174-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-169
09923–7821009924–74510
Bearing installer Bearing and oil seal handle
)) / ) / ) / ) / ) / ) / )
09925–37811–001 09925–88210
Oil pressure gauge Bearing puller attachment
)) / )
09925–98210 09925–98221
Input shaft bearing inst aller Bearing installer
))
09926–37610 09926–37610–001
Bearing remover Bearing puller
) / )) / )
09926–37610–002 09926–37610–003
Bearing puller attachment Bearing remover attachment
) / )) / )
09926–58010 09926–96030
Bearing remover attachment Clutch spring compressor
No.7
)) / )
09926–96050 09926–97610
Brake piston compressor Spring compressor
) / )) / )
09926–97620 09926–98310
Spring compressor Clutch spring compressor
) / )) / )

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 Clutch: 5C-1
Transmission / Transaxle
Clutch
General Description
Clutch ConstructionS7RS0B5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positione d on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal c auses the release bearing to advance and pushes on the tips of the tapered fingers of
the diaphragm spring. When this happens, the diaphragm sp ring pulls the pressure plate away from the flywheel,
thereby interrupting the flow of drive from flywheel through clutch disc to transaxle input shaft. Clutch fluid is supplied
from brake fluid reservoir. Clutch fluid level can be checked by brake fluid level of brake fluid reservoir.
[A]: For petrol engine model2. Flywheel5. Clutch cover 8. Input shaft bearing
[B]: For diesel engine model 3. Clutch disc6. Diaphragm spring 9. Input shaft
1. Crankshaft 4. Pressure plate7. Release bearing 10. Release shaft
I4RS0A530001-01