Brake SUZUKI SWIFT 2007 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-151
6) Install parking lock pawl bracket (1) to transaxle
case.
Tightening torque
Parking lock pawl bracket bolt (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
7) After applying A/T fluid to new O-rings, install them to 1st and reverse brake piston (3).
8) Install 1st and reverse brake piston (1) to transaxle case (2).
NOTE
Be careful not to damage O-ring when
installing 1st and reverse brake piston.

9) Install 1st and reverse brake return spring subassembly (1) to transaxle case (2).
10) Apply A/T fluid to 1st and reverse brake discs (2), separator plates (3) and retaining plate (1), then
install them to transaxle case.
11) Compress 1st and reverse brake return spring using special tool and hydraulic press, then attach snap
ring.
CAUTION!
Do not damage 1st and reverse brake return
spring subassembly discs, plates and piston
by pressing in 1st and reverse brake return
spring subassembly passing through its
original installing position over 0.8 mm (0.031
in.).

Special tool
(A): 09926–97620
1. Inner O-ring 2. Outer O-ring
I2RH0B510262-01
I2RH0B510263-01
I2RH0B510264-01
I2RH0B510265-01
I2RH0B510266-01
I2RH0B510267-01

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-154 Automatic Transmission/Transaxle:
20) Check for correct installation of planetary gear assembly as follows.
Measure the distance “a” by using micrometer
caliper (1) and straightedge (2). If measured value is
out of specification, remove planetary gear assembly
and reinstall it properly.
Distance between planetary gear assembly and
mating surface of transaxle case
“a”: More than 49.9 m (1.965 in.)
21) Apply A/T fluid to one-way clutch No.2 assembly (1), then install it to planetar y gear assembly. After that,
ensure that planetary carrier rotates only in
counterclockwise direction “A”, not in clockwise
direction “B”. 22) Install one-way clutch outer race retainer (1).
23) Apply A/T fluid to new brake drum gasket (1), then
install it to transaxle case.
24) Apply A/T fluid to 2nd brak e retaining plate (1), discs
(2) and separator plates (3), then install them to
transaxle case.
25) Install 2nd brake return spring subassembly (1) to transaxle case.
“a”
“a”
2 1
I2RH0B510276-01
I2RH0B510277-01
I2RH0B510278-01
I2RH0B510279-01
2
3
1
I2RH0B510280-01
1
I2RH0B510281-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-155
26) Apply A/T fluid to 2nd brake piston assembly (1), and align the projection of 2nd brake piston assembly
with the groove of transaxle case, then put together.
27) Install 2nd brake piston snap ring (1) by using special tool and hydraulic press.
CAUTION!
Do not damage 2nd brake piston assembly,
return spring subassembly, plates and discs
by pressing in 2nd brake assembly passing
through its original installing position over
0.4 mm (0.016 in.).

Special tool
(A): 09926–96050
28) After applying A/T fluid to front sun gear thrust bearing race (2), install it to front planetary sun gear
(1). 29) Apply A/T fluid to front planetary sun gear (1) and
install it to planetary gear assembly (2).
30) Install O/D and 2nd coast brake retaining plate snap ring (1).
CAUTION!
Be sure to install O/D and 2nd coast brake
retaining plate snap ring correctly in groove
of transaxle case.

31) After applying grease to slide contact face of planetary carrier thrust washer (1), install it to
planetary gear assembly.
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
I2RH0B510282-01
I2RH0B510283-01
I2RH0B510285-01
I2RH0B510286-01
I2RH0B510287-01
I2RH0B510288-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-157
38) After applying A/T fluid to intermediate shaft thrust bearing rear race (3), thrust bearing (2) and front
race (1), install them to forward and reverse clutch
assembly (4).
Bearing race dimension
39) Apply A/T fluid to forward and reverse clutch assembly (1).
Install forward and revers e clutch assembly while
rotating clockwise and co unterclockwise frequently
to fit clutch discs to mating hubs.
NOTE
Before installation, align teeth of forward and
reverse clutch discs to facilitate installation.

40) Check for correct installation of forward and reverse clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
forward and reverse clutch assembly, forward clutch
hub, rear planetary sun gear subassembly and one-
way clutch No.1 assemb ly, and reinstall them
properly.
Distance between forward and reverse clutch
assembly and mating surface of transaxle case
“a”: Less than 29.4 mm (1.157 in.)
41) After applying A/T fluid to O/D and 2nd coast brake retaining plate (4), separator plate (3), discs (2) and
rear plate (1), install th em to transaxle case (5).
Front race Rear race
Outside
diameter 30.6 mm (1.20 in.) 28.2 mm (1.11 in.)
Thickness 2.0 mm (0.08 in.) 2.0 mm (0.08 in.)
I2RH0B510294-01
I2RH0B510295-01
“a”
“a”
1 2
I2RH0B510296-01
I2RH0B510297-01

Downloaded from www.Manualslib.com manuals search engine 5A-158 Automatic Transmission/Transaxle:
42) Measure O/D and 2nd coast brake piston stroke.• Measure dimension “a” from end face 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.)
When piston stroke is out of specification, select O/D
and 2nd coast brake rear plate with proper thickness
from among the following table and replace it.
Available O/D and 2nd coast brake rear plate
thickness
43) After applying A/T fluid to new 2nd brake gaskets (1), install them to transaxle case (2).
44) After applying A/T fluid to reverse clutch drum thrust bearing (1), install it to forward and reverse clutch
assembly (2).
45) Remove sealant attached to mating surface of transaxle rear cover (1) completely.
46) Apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Thickness Identification mark
1.8 mm (0.071 in.) 1
2.0 mm (0.079 in.) 2
2.2 mm (0.087 in.) 3
2.4 mm (0.094 in.) 4
2.6 mm (0.102 in.) 5
I2RH0B510298-01
I2RH0B510299-01
I2RH0B510300-01
“A” 2
1
I2RH0B510301-01

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 5A-168 Automatic Transmission/Transaxle:
Special Tools and Equipment
Recommended Service MaterialS7RS0B5108001
NOTE
Required service material is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Direct Clutch Assembly Components”
“Forward and Reverse Clutch Assembly Components”
“2nd Brake Piston Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Countershaft Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Special ToolS7RS0B5108002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / )
SUZUKI Super Grease C P/No.: 99000–25030) / ) / ) / ) / ) / )
Sealant SUZUKI Bond No.1216B P/No.: 99000–31230) / ) / )
09900–20605 09900–20607
Dial calipers (1/100 mm, 10-
34 mm) Dial gauge
) / ) / )) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )
09900–20701 09913–50121
Magnetic stand Oil seal remover
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) )
09913–61510 09913–70123
Bearing puller Bearing installing tool
)) / )
09913–84510 09913–85210
Bearing installer Bearing installer
) / ) / ) / ))

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-1
Transmission / Transaxle
Manual Transmission/Transaxle
General Description
Manual Transaxle Construction and ServicingS7RS0B5201001
The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs and three shafts
(input shaft, countershaft and reverse gear shaft). All forward gears are in constant mesh, and reverse uses a sliding
idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is don e on input shaft and engaged with input shaft 3rd gear or
4th gear. The 5th speed synchronizer sleev e & hub on input shaft is engaged with input shaft fifth gear mounted on the
input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used.
The device utilizes the 5th synchromesh, which is the lever synchro type, to appl y the brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of
shifting to 2nd gear.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
For servicing, it is ne cessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tight ened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.
Further, care must be taken to adjust preload of count ershaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.