Brake SUZUKI SWIFT 2007 2.G Service Workshop Manual

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-42 Automatic Transmission/Transaxle:
No Lock-Up OccursS7RS0B5104020
System Description
TCM turns TCC solenoid OFF under any of the following conditions.
• Brake light switch is turned ON (Brake pedal is depressed).
• Transmission fluid temperat ure is less than 60 °C (140 °F).
• Throttle opening is as much as 0%.
• TCM detects the following DTCs. P0705 / P0707 / P0712 / P0713 / P0717 / P0722 / P0787 / P0788 / P0961 / P0962 / P0963 / P0973 / P0974 / P0976
/ P0977 / P1702 / P1703 / P1774 / P1777 / P2762 / P2763 / P2764
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.

3 1) Perform running test under the following conditions and measure voltage between terminal “C34-16” of TCM
connector and ground, terminal “C34-15” of TCM
connector and ground.
• Engine coolant temperature is in normal operating temperature.
• Select lever is in “D” range.
• Drive vehicle with 4th gear condition referring to “Automatic Gear Shift Table”.
Voltage between TCM connector and ground
Between terminal “C34-16” of TCM connector and
ground: 0 – 1 V
Between terminal “C34-15” of TCM connector and
ground: 8 – 14 V
Do results satisfy the value? Faulty shift solenoid
valve, circuit or
transaxle.
“BRN” circuit shorted to
power circuit or open, or
“BLK/YEL” circuit
shorted to ground. If
wire is OK, go to Step 4.
4 “3” position switch signal inspection
1) With ignition switch turned ON, check voltage between
“L01-8” terminal of BCM coupler and ground.
“3” position switch signal specification
Shift select lever to “3” or “2” range: 8 – 14 V
Shift select lever to other above range: 0 – 1 V
Is result as specified? Substitute a known-
good TCM and recheck.
Faulty “3” position
switch or its circuit.
Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-43
Transmission Warning Light Circuit Check – Light Does Not Come “ON” at Ignition Switch ONS7RS0B5104021
Troubleshooting
Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ONS7RS0B5104022
TroubleshootingStep Action Yes No
1 Was “A/T System Check” performed? Go to Step 2. Go to “A/T System
Check”.
2 Check DTC
Is DTC P0705, P0707, P0712, P0713, P0717, P0722,
P0787, P0788, P0961, P0962, P0963, P0973, P0974,
P0976, P0977, P1702, P1703, P1774, P1777, P2762,
P2763 and/or P2764 detected? Go to applicable DTC
diag. flow.
Go to Step 3.
3 Brake light switch signal inspection
1) With ignition switch turned ON, check voltage between
terminal “C35-20” of ECM connector and ground.
Brake light switch signal specification
Brake pedal is released: 0 – 1 V
Brake pedal is depressed: 8 – 14 V
Is result as specified? Substitute a known-
good TCM and recheck.
Mis-adjusted brake light
switch or faulty brake
light switch.
Step
Action YesNo
1 Combination meter power supply check
1) Turn ignition switch ON.
Does other indicator / warnin g lights in combination meter
comes ON? Go to Step 2.
Repair combination
meter power supply
circuit referring to “C-1
Combination Meter
Circuit Diagram (Meter)
in Section 9A”.
2 TCM power and ground circuit check
1) Check referring to “TCM Power and Ground Circuit
Check”.
Is it in good condition? Go to Step 3.
Repair or replace.
3 DTC check
1) Check DTC referring to “DTC Check”.
Is there DTC P1774? Go to applicable DTC
diag. flow.
Go to Step 4.
4 Combination meter function check
1) Turn ignition switch ON.
Does A/T selector position in dicator show correct select
lever position? Replace combination
meter.
Substitute a known-
good TCM and recheck.
Step
Action YesNo
1 Diagnostic Trouble Code (DTC) Check
1) Check DTC referring to “DTC Check”.
Is there any DTC(s)? Perform DTC Flow to
repair and retry.
Substitute a known-
good TCM and recheck.
If OK, substitute a
known-good
combination meter and
recheck.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-87
Troubleshooting
Brake Interlock System InspectionS7RS0B5104047
1) Check that select lever cannot be moved to any other range from “P” range position when ignition
switch key is at ACC position, at LOCK position or it
is removed from keyhole of ignition switch, or brake
pedal is not depressed. 2) Shift select lever to “P” range position, release knob
button and check for the following.
• Ignition key can be turned between LOCK and ACC positions back and forth and also it can be
removed from ignition switch.
Step Action Yes No
1 Check TCM back-up power circuit
1) Disconnect TCM connector with ignition switch OFF.
2) Check for proper connection to TCM at “C34-24”
terminal.
3) If OK, check voltage at terminal “C34-24” of disconnected TCM connector.
Is it 10 – 14 V? Go to Step 2. “WHT/RED” circuit open
or shorted to ground.
2 Check TCM power circuit
1) Disconnect TCM connector with ignition switch OFF.
2) Check for proper connection to TCM at “C34-6” terminal.
3) If OK, turn ignition switch ON and check voltage at
terminal “C34-6” of disconnected TCM connector.
Is it 10 – 14 V? Go to Step 4. Go to Step 3.
3 Check A/T relay operation
1) Check A/T relay operation referring to “A/T Relay
Inspection”.
Is check result satisfactory? “YEL/BLK”, “YEL/BLU”,
“LT GRN/BLK” or “BLK”
circuit for power supply
open.
Replace A/T relay.
4 Check TCM ground circuit
1) Turn ignition switch OFF.
2) With TCM connectors disconnected, check for proper
connection to TCM at “C34-1” / “C34-23” terminal.
3) If OK, check resistance between “C34-1” / “C34-23” terminal of disconnected TCM connector and body
ground.
Is continuity indicated? TCM power and ground
circuits are in good
condition.
“BLK” circuit for TCM
ground open.
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Downloaded from www.Manualslib.com manuals search engine 5A-88 Automatic Transmission/Transaxle:
• With ignition switch turned to ACC position, push
shift lock solenoid release button (1). Then, select
lever can be shifted from “P” range position to any
other range.
• While ignition switch is at LOCK position, even when shift lock solenoid release button (1) is
pressed, select lever cannot be shifted from P
range position to any other range.
• When ignition switch is turned ON and brake pedal is depressed, select lever can be shifted
from “P” range position to any other range. 3) With select lever shifted to any position other than
“P” range, check that ignition key cannot be turned
LOCK position and it cannot be removed from
ignition switch unless it is at LOCK position.
Repair Instructions
Learning Control InitializationS7RS0B5106001
1) Connect san tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
2) Start engine and shift select lever to “P” range.
3) Select “Misc Test” mode on scan tool.
4) Perform “AT learned initialize” on scan tool.
1
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-89
A/T Fluid Level CheckS7RS0B5106002
CAUTION!
Do not use any fluid other than the specified
ATF. Use of any fluid other than the specified
ATF may cause juddering or some other
faulty condition to occur.

Level Check at Normal Operating (Hot) Temperature
– Hot Check1) Drive vehicle so that A/T fluid temperature reach the
normal operating temperature (70 – 80 °C (158 –
176 °F)).
2) Stop vehicle with engine running and place it level.
3) With select lever at “P” range, apply parking brake and place chocks against wheels.
4) Keep engine idling and shift selector slowly to “L” and back to “P” position.
5) With engine idling, pull out fluid level gauge, wipe it off with a clean cloth and put it back into place.
6) Pull out fluid level gauge (1) again and check fluid level indicated on it. The lo west fluid level should be
between FULL HOT (2) and LOW HOT (3). If it is
below LOW HOT, add SUZUKI ATF 3317 or Mobil
ATF 3309 up to FULL HOT.
Automatic transaxle fluid
SUZUKI ATF 3317 or Mobil ATF 3309
NOTE
• Do not race engine while checking fluid level, even after the engine start.
• Do not overfill. Overfilling can cause foaming and loss of fluid through breather.
Then slippage and transaxle failure can
result.
• Bringing the level from LOW HOT to FULL HOT requires 0.4 liters (0.85 / 0.70 US/Imp.
pt).
• If vehicle was driven under high load such as pulling a trailer, fluid level should be
checked about half an hour after it is
stopped.

Level Check at Room (Cold) Temperature – Cold
Check
Fluid level can be checked temporarily at room (cold)
temperature which correspond to 20 – 30 °C (68 – 86
° F). This level check is considered to be preparation
before performing level check under normal operating
(hot) temperature. Checking procedure itself is the same
as that described in “Level Check at Normal Operating
(Hot) Temperature – Hot Check: ”. If fluid level is
between “FULL COLD” (4) and “LOW COLD” (5),
proceed to test drive. And when fluid temperature has
reached normal operating temp erature, check fluid level
again and adjust it as necessary.
CAUTION!
Fluid level check at room (cold) temperature
is recommended only for preparation of level
check under normal (hot) operating
condition.
Failure to perform fluid level check under
normal (hot) operating temperature may
result in damage to transaxle.

4. “FULL COLD” mark 5. “LOW COLD” mark
1. Fluid level gauge 2. “FULL HOT” mark 3. “LOW HOT” mark
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Downloaded from www.Manualslib.com manuals search engine 5A-92 Automatic Transmission/Transaxle:
Select Cable ComponentsS7RS0B5106011
Select Cable Removal and InstallationS7RS0B5106012
Removal
1) Remove parking brake lever cover.
2) Remove console box.
3) Disconnect select cable from select lever and then detach from bracket.
4) Remove clip and disconnect select cable from manual select lever.
5) Remove select cable retainer from dash panel. Installation
Install select cable by reversing removal procedure.
The important steps in inst
allation are as follows.
• Apply grease to pin and cable joint.
• Tighten bolts to specified torque referring to “Select Cable Components”.
• Adjusting procedure is as follows. Refer to “Select Cable Adjustment”.
(a)
11
3
10
9
6
8 4
5
(b)
7
1
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1. Select lever assembly
6. Clip 11. Lock
2. Select cable 7. Select cable retainer bolt : 23 N⋅m (2.0 kgf-m, 17.0 lb-ft)
3. Select cable retainer 8. Manual select lever pin
: Apply lithium grease 99000-25011 to all around pin (0.15 g) :5.0 N
⋅m (0.55 kgf-m, 4.0 lb-ft)
4. Cable bracket 9. Select lever pin
: Apply lithium grease 99000-25011 to all around pin (0.15 g)
5. Manual select lever 10. Adjuster case

Downloaded from www.Manualslib.com manuals search engine 5A-94 Automatic Transmission/Transaxle:
5) Turn ignition switch to LOCK position.
6) Remove parking brake cover and console box.
7) Detach cable end (1) from interlock cam (2) while
pressing claws (3) of interlock cam boss.
At this time, be careful no t to cause damage to its
claws.
Detach cable casing cap (4 ) from selector bracket
(5) while pressing check hook.
8) Remove interlock cable.
Installation 1) Lay interlock cable to its original cabling route.
2) Turn ignition switch to ACC position.
3) Insert cable casing cap (1) into key cylinder cover (2) securely. 4) Pull out lock button (1) of selector side cable end (2).
4
5 31
2
4
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1 2
3
4
5 6 7
8
2
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1. Key interlock cable 4. Key cylinder cover7. Brake switch bracket
2. Clamp 5. Select lever assembly 8. Wiring harness
3. Steering lock assembly / Steering lock unit (Keyless start model) 6. EPS control module
9. Marking
1
2
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1
1
2
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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-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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