Transmission fluid oil SUZUKI SWIFT 2006 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-145
Reassembly1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque
converter housing.
Tightening torque
Torque converter housing plug (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
2) Using special tools, assemble differential side RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
3) Using special tool, install countershaft RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
4) Using special tools, install new differential side oil seal to torque converter housing.
Special tool
(A): 09924–74510
(B): 09944–88220 Differential side oil seal installing depth
“a”: 2.6 – 3.6 mm (0.10 – 0.14 in.)
5) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
6) Install lubrication LH tube (1) and RH tube (2).
7) Install fluid reservoir RH plate (1) and lubrication tube clamp (2).
Tightening torque
Lubrication tube clamp bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
Fluid reservoir RH plate bolt (b): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
I2RH0B510242-01
(A)
(B)
I3RM0B510063-01
(B) (A)
I3RM0B510064-01
I2RH0B510245-02
I2RH0B510237-01
I2RH0B510246-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
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.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

I2RH0B510252-01
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01

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 5A-152 Automatic Transmission/Transaxle:
12) Install 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations
as shown in figure.
13) Using special tools, meas ure 1st and reverse brake
piston stroke when compressed air (400 – 800 kPa,
4 – 8 kg/cm
2, 57 – 113 psi) is brown through oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.791 – 1.489 mm (0.0311 – 0.0586 in.) 14) Install reduction drive gear (1) to transaxle case (3)
by using special tools and hydraulic press.
CAUTION!
• Do not use transaxle case as groundwork to press fit reduction drive gear.
• 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.

NOTE
When replacing reduction drive gear, replace
it together with reduction driven gear as a
set.

Special tool
(A): 09951–18210
(B): 09944–78210
15) Install parking lock pawl (1) and spring (2). Apply A/T fluid to parking lock pawl sh aft, then insert it into
transaxle case.
[A]: Correct [B]: Incorrect
I2RH0B510268-01
I2RH0B510269-01
2. Stand that can slightly lift transaxle case.
I2RH0B510270-01
I2RH0B510271-01

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 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 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-9
Manual Transaxle Unit Dismounting and
Remounting
S7RS0B5206009
Dismounting1) Drain coolant and transaxle oil.
2) Remove coolant reservoir with reservoir hose.
3) Remove battery and tray.
4) Remove air cleaner case and resonator.
5) Disconnect gear shift and gear select control cables (1) while pressing claws (2) of clip (3).
6) Disconnect back up light switch coupler and undo wiring harness clamps.
7) Remove ground cable from transaxle.
8) Remove clutch operating cylinder with fluid hose from transaxle.
9) Remove water inlet No.2 pipe from transaxle.
10) Remove starting motor re ferring to “Starting Motor
Dismounting and Remounting in Section 1I”.
11) Remove transaxle to engine bolts (1) of upper side. 12) Support engine using supporting device (1).
CAUTION!
Do not apply supporting device to projection
part A. If do so, it may be deformed.

13) Remove front drive shafts and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
14) Remove exhaust No.2 pipe referring to “Exhaust Pipe and Muffler Removal a nd Installation in Section
1K”.
15) Remove clutch housing lower plate (1).
1
2
3
I7RS0A521003-01
1
1
I4RS0A520018-01
1
A
I4RS0A520019-01
1I4RS0A520020-01

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

Downloaded from www.Manualslib.com manuals search engine Instrumentation / Driver Info. / Horn: 9C-2
Combination Meter Reception Data
NOTE
*:ESP® model

ECM BCM
Keyless
Start
Control Module
(if equipped)
Combination Meter
TCM
(A/T model)
Engine speed signal
Immobilizer indicator light control signal
Vehicle speed signal
Engine coolant temperature signal
MIL control signal
Transmission range sensor signal
Transmission warning light signal
Diagnostic trouble code (DTC)
Brake fluid level switch signal
(brake warning light control signal)
Driver side seat belt buckle switch signal
(seat belt reminder light control signal)
Charging system warning light signal
(charge warning light control signal)
Engine oil pressure switch signal
(oil pressure warning light control signal)
Parking brake switch signal
(brake warning light control signal)
Illumination ON signal
Door switch signal
(open door warning light control signal)
ABS indication signal
EBD indication signal
(brake warning light control signal)
Key indicator light control signal ABS/ESP®
ControlModule
DATA
Receive
*
ESP® status signal
I7RS0B930001-01