oil plug SUZUKI SWIFT 2006 2.G Service Service 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 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-113
19) Remove transaxle case plug (1).
20) Remove torque converter housing bolts.
21) Remove torque converter housing (1) while tapping
around it lightly with plastic hammer.
22) Remove breather hose (1).
23) Remove breather union (2).
24) Measure input shaft thrust play. Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
When input shaft thrust play is out of specification,
select input shaft front th rust bearing with proper
thickness from among the list below and replace it.
Special tool
(A): 09900–20607
(B): 09900-20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
Available input shaft front thrust bearing
thickness
: 3.45, 4.05 mm (0.136, 0.159 in.) 25) Remove oil pump assembly (1).
26) Remove direct clutch assembly (1).
27) Remove input shaft front thrust bearing (1).
NOTE
If input shaft front thrust bearing is not
found, it may have been taken out with oil
pump assembly.

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Downloaded from www.Manualslib.com manuals search engine 5A-136 Automatic Transmission/Transaxle:
Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Disassembly and
Reassembly
S7RS0B5106048
Disassembly1) Remove snap ring by using special tools and hydraulic press.
Special tool
(A): 09926–96030
(B): 09946–06710
CAUTION!
Do not press O/D and 2nd coast brake return
spring subassembly in over 1.0 mm (0.039
in.).
Excessive compression may cause damage
to O/D and 2nd coast brake return spring
subassembly and/or piston.

2) Remove O/D and 2nd coast brake return spring assembly.
3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (2) of transaxle rear cover (1)
to remove O/D and 2nd coast brake piston. 4) Remove O/D and 2nd coast brake piston front O-ring
(1) and rear O-ring (2).
5) Remove rear cove r seal rings (1).
6) Remove rear cover plugs (1).
1. Transaxle rear cover
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Downloaded from www.Manualslib.com manuals search engine 5A-144 Automatic Transmission/Transaxle:
Torque Converter Housing Disassembly and
Reassembly
S7RS0B5106057
Disassembly1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2).
2) Remove lubrication LH tube (1) and RH tube (2).
NOTE
Do not bend lubrication tube with excessive
force.

3) Remove differential side oil seal (1). 4) Remove countershaft RH bearing cup by using
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
5) Remove differential side RH bearing cup by using special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
6) Remove torque converter case plugs (1).
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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)
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(B)
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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 5B-4 Manual Transmission/Transaxle:
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Differential Side Oil Seal ReplacementS7RS0B5206002
1) Lift up vehicle and drain transaxle oil.
2) Remove front drive shaft and/or center shaft referring to “Front Driv e Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
4) Install oil seal (1) facing its spring side inward. Use special tool and hammer for installation.
Special tool
(A): 09913–85210
5) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make
sure of its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
6) Insert front drive shaft and/or center shaft referring to “Front Drive Shaft A ssembly Removal and
Installation in Section 3A”.
7) Fill transaxle oil as specified referring to “Manual Transaxle Oil Change”, and make sure that oil has
been sealed with oil seal.
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