disc SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5A-98 Automatic Transmission/Transaxle:
Transmission Fluid Temperature Sensor
Inspection
S7RS0B5106021
Warm up transmission fluid temperature sensor (2).
Check resistance between terminals of valve body
harness connector (1). Thus make sure its resistance
decrease as its temperature increase.
Transmission fluid temperature sensor resistance
10 °C (50 °F): 5.8 – 7.1 k Ω
110 °C (230 °F): 231 – 263 Ω
145 °C (293 °F): 105 – 117 Ω
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation
S7RS0B5106022
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N· m (1.7 kgf-m, 12.5 lb-ft)
5) Remove A/T oil pan (1) and oil pan gasket (2).
6) Remove oil strain er assembly (3). 7) Remove transmission fluid temperature sensor (1)
from sensor clamp.
8) Disconnect solenoid connectors (2).
9) Remove shift solenoid va lve-A (No.1) (1), shift
solenoid valve-B (No.2) (2) and timing solenoid valve
(3) by removing bolts.
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-101
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Pressure Control
Solenoid) Removal and Installation
S7RS0B5106024
Removal1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
5) Remove A/T oil pan (1) and oil pan gasket (2).
6) Remove oil strain er assembly (3).
7) Remove transmission fluid temperature sensor (1) from sensor clamp.
8) Disconnect solenoid connectors (2). 9) Remove valve body assembly referring to
“Automatic Transaxl e Unit Disassembly”.
10) Remove pressure control solenoid valve and TCC pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC pressure control solenoid va lve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body asse mbly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “A utomatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valve InspectionS7RS0B5106025
CAUTION!
• Be very careful as dust etc. does enter when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)
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Downloaded from www.Manualslib.com manuals search engine 5A-102 Automatic Transmission/Transaxle:
Operation Check
Check pressure control solenoid valves (Pressure
control solenoid and TCC pressure control solenoid)
operation in the either manner of the following.
Using regulated DC power supply
1) Connect pressure contro l solenoid valve (1) with
regulated DC power supply (2) as shown in figure.
2) Turn regulated DC power supply switch ON and increase voltage of power supply keeping current
within 1.0 A.
3) Check for gradual movement of valve (3) in the direction of arrow “A” as voltage is increased.
4) Check movement of valve (3) in the direction of arrow “B” as voltage is decreased.
5) Turn power supply switch OFF.
CAUTION!
Do not pass current 1.0 A or more, or
pressure control solenoid is burned out.

Not using regulated DC power supply 1) Connect pressure control solenoid valve (1) to battery (2) setting 21 W bulb (4) on the way as
shown in figure.
2) Check for movement of valve (3) in the direction of arrow “A”.
3) Disconnect pressure control solenoid valve (1) from battery (2) and check movement of valve (3) in the
direction of arrow “B” as shown in figure.
CAUTION!
Set 21 W bulb on the way, or pressure control
solenoid valve is burned out.

Transmission Control Module (TCM) Removal
and Installation
S7RS0B5106026
CAUTION!
• TCM and ECM consists of highly precise
parts, therefore when handling it, be
careful not to expose to excessive shock.
• When replacing TCM with used one, all learned contents, which have been stored
in TCM memory by executing learning
control, should be initialized after
replacement.

Removal
1) Disconnect negative cable at battery.
2) If the vehicle is equipped with air bag system, disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Disconnect connectors from TCM (1).
4) Remove TCM by removing its bolts.
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Installation
Reverse removal procedure noting the following.
• Connect TCM connectors securely.
• If the vehicle is equipped with air bag system, be sure to enable air bag system after TCM is back in place.
Refer to “Enabling Air Bag System in Section 8B”.
A/T Relay InspectionS7RS0B5106027
1) Disconnect negative cable at battery.
2) Remove A/T relay (2) from fuse and relay box (1).
3) Check that there is no continuity between terminal “C” and “D”.
If continuity is indicated, replace A/T relay.
4) Connect battery positive (+ ) terminal to terminal “A”
of A/T relay and battery negative (–) terminal to
terminal “B” of A/T relay.
Check continuity between terminal “C” and “D” of A/T
relay.
If continuity does not indicated, replace A/T relay.
Differential Side Oil Seal ReplacementS7RS0B5106028
1) Lift up vehicle and drain automatic transaxle fluid.
2) Remove drive shaft joints from differential gear of transaxle. Refer to “Front Drive Shaft Assembly
Removal and Installation in Section 3A” for
procedure to disconnect drive shaft joints.
For differential side oil seal removal, it is not
necessary to remove drive shafts from steering
knuckle.
3) Remove differential side oil seal (1) by using screwdriver or the like.
"D"
"B" "A"
"C"
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Downloaded from www.Manualslib.com manuals search engine A u to m a tic Tra n s m is s io n /Tra n s a x le : 5 A -1 0 9
1. Torque converter37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing : Apply sealant 99000-31230 to mating
surface to transaxle case. 38. Cooler check valve
74. Rear sun gear thrust bearing race
3. Oil strainer assembly : Replace oil strainer when overhauling. 39. Spring
75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely. 84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal : Apply grease 99000-25030 to oil seal
lip. 49. Reduction drive gear
85. Rear cover seal ring
14. Differential side oil seal : Apply grease 99000-25030 to oil seal
lip. 50. Planetary ring gear subassembly
86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly 93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc : Do not reuse.
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Apply automatic transaxle fluid.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 23 N⋅m (2.3 kgf-m, 17 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 25 N⋅m (2.5 kgf-m, 18 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face. : 7.5 N
⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 22 N⋅m (2.2 kgf-m, 16 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 7 N⋅m (0.7 kgf-m, 5.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 17 N⋅m (1.7 kgf-m,12.5 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 29 N⋅m (2.9 kgf-m, 21 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-111
8) Remove fluid cooler pipes (1) and pipe union (2).
9) Remove fluid level gauge (3) and fluid filler tube (4).
10) Remove oil pan (1) and oil pan gasket (2).
NOTE
• For removal of oil pan, do not turn transaxle over as this will contaminate
valve body with foreign materials in
bottom of oil pan.
• When removing oil pan, tap around it lightly with plastic ha mmer. Do not force it
off by using screwdriver or the like.

11) Remove oil strain er assembly (1). 12) Disconnect connectors (2) from solenoid valves and
transmission fluid temperature sensor (1).
13) Remove valve body assembly bolts.
CAUTION!
Be careful not to let manual valve fall off
when removing valve body assembly.

NOTE
There are five kinds of bolts (bolts A (1), B (2),
C (3), D (4) and E (5)) fixing valve body
assembly.

14) Remove manual valve rod (1) from manual valve lever (2), then remove valve body assembly (3).
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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 Automatic Transmission/Transaxle: 5A-117
47) Remove O/D and 2nd coast brake retaining plate snap ring (1).
48) Remove front planetary sun gear (1).
49) Remove front sun gear thrust bearing race (2) from front planetary sun gear (1).
50) Using special tool and hydraulic press, remove 2nd brake piston snap ring (1).
CAUTION!
Do not press 2nd brake piston assembly in
over 0.4 mm (0.016 in.).
Excessive compression may cause damage
to piston assembly, return spring, plates and/
or discs.

Special tool
(A): 09926–96050 51) Remove 2nd brake piston assembly (1).
52) Remove 2nd brake return spring subassembly (2).
53) Remove 2nd brake separator plates (1), discs (2)
and retaining plate (3).
54) Remove brake drum gasket (1).
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Downloaded from www.Manualslib.com manuals search engine 5A-118 Automatic Transmission/Transaxle:
55) Remove one-way clutch outer race retainer (1).
56) Check one-way clutch No.2 as follows.• Ensure planetary carrier (1) rotates only in counterclockwise direction “A”, never in clockwise
direction “B”.
• If the planetary carrier rotates both ways or does not rotate either way, one-way clutch No.2
assembly will need to be replaced with new one-
way clutch No.2 assembly.
57) Remove one-way clutch No.2 assembly (1). 58) Remove planetary gear assembly (1).
59) Measure 1st and reverse brake piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace discs and plates.
• Using special tool, measure 1st and reserve brake piston stroke when compressed air (400 – 800
kPa, 4 – 8 kg/cm
2, 57 – 113 psi) is blown through
oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.79 – 1.49 mm (0.031 – 0.059 in.)
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-119
60) Remove snap ring while the 1st and reverse brake piston return springs are compressed using special
tool and hydraulic press.
CAUTION!
Do not press 1st and reverse brake return
spring subassembly in over 0.8 mm (0.031
in.).
Excessive compression may cause damage
to return spring subassembly, discs, plates
and/or piston.

Special tool
(A): 09926–97620
61) Remove 1st and reverse brake retaining plate, discs and separator plates.
62) Remove 1st and reverse brake return spring subassembly (1).
63) Turn over transaxle and uncaulk reduction drive gear nut (1). 64) Secure reduction drive gear (1) with parking lock
pawl, then remove reduction drive gear nut.
CAUTION!
• It is recommended that this operation should be carried out on rubber mat to
prevent damaging transaxle case.
• Never reuse removed nut.

65) Using special tools and hydraulic press, remove planetary ring gear subassembly (1).
CAUTION!
Do not reuse planetary ring gear
subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.

Special tool
(A): 09913–84510
(B): 09923–78210
66) Remove parking lock pawl shaft, then spring (2) and parking lock pawl (1).
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