ect removal SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-97
Installation1) Apply A/T fluid to input shaft speed sensor O-ring.
2) Install input shaft speed se nsor (1) to A/T case and
tighten bolt to specified torque.
Tightening torque
Input shaft speed sensor bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
3) Connect input shaft speed sensor connector (2) to input shaft speed sensor (1).
4) Connect negative cable to battery.
Input Shaft Speed Sensor InspectionS7RS0B5106019
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Check resistance between input shaft speed sensor (1) terminals.
Input shaft speed sensor resistance
Standard: 560 – 680 Ω at 20 °C (68 °F)
Transmission Fluid Temperature Sensor
Removal and Installation
S7RS0B5106020
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) With engine is cool, remove drain plug and drain A/T fluid.
4) Install drain plug. Refer to “A/T Fluid Change”.
5) Remove A/T oil pan.
6) Remove oil stra iner assembly. 7) Remove valve body assembly referring to
“Automatic Transaxl e Unit Disassembly”.
CAUTION!
When pulling solenoid wire harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

8) Remove solenoid wire harness (1).
Installation
Reverse removal procedure to install solenoid wire
harness and valve body assembly noting the following
points.
• For details of valve body assembly and their connectors installation, refer to “Automatic Transaxle
Unit Assembly”.
• For details of A/T oil pa n installation, refer to
“Automatic Transaxle Unit Assembly”. Use new oil
pan gasket.
• Tighten valve body harness connector bolt to specified torque.
Tightening torque
Valve body harness connector bolt (a): 7.0 N·m (
0.7 kgf-m, 5.0 lb-ft)
• 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.
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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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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
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"
1
2
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Downloaded from www.Manualslib.com manuals search engine 5A-104 Automatic Transmission/Transaxle:
4) Apply grease to new differential side oil seal lips.: Grease 99000–25030 (SUZUKI Super Grease C)
5) Install new differential side oil seals (1) by using special tool.
Special tool
(C): 09944–88220
(D): 09924–74510
Differential side oil seal installing depth
Right side “a”: 2.6 – 3.6 mm (0.10 – 0.14 in.)
Left side “b”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
6) Install drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”.
7) Pour A/T fluid referring to “A/T Fluid Change”.
A/T Fluid Cooler Hoses ReplacementS7RS0B5106029
The rubber hoses for the A/T fluid cooler should be
checked at specified interval. If replacing them, be sure
to note the following.
• to replace clamps at the same time
• to insert hose as far as its limit mark
• to clamp clamps securely
[A]: Right side [B]: Left side
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1. Inlet hose (Outlet from A/T fluid cooler)
2. Outlet hose (Inlet to A/T fluid cooler)
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Downloaded from www.Manualslib.com manuals search engine 5A-106 Automatic Transmission/Transaxle:
Automatic Transaxle Unit Dismounting and
Remounting
S7RS0B5106031
Dismounting1) Take down transaxle with engine. For its procedure, refer to “Engine Assembly Removal and Installation
in Section 1D”.
2) Remove transaxle housing lower plates (1).
3) Remove drive plate to torque converter bolts (1) engage flat head rod or the like (2) with drive plate
ring gear. 4) Remove starting motor.
5) Remove bolts and nut fastening engine and
transaxle, then detach transaxle from engine.WARNING!
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
the work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.

NOTE
When detaching transaxle from engine, move
it in parallel with cranks haft and use care so
as not to apply excessive force to drive plate
and torque converter.

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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-107
Remounting1) Make sure that torque converter is installed correctly to transaxle.
Refer to “Automatic Transaxle Unit Assembly”.
2) Attach transaxle to engine.
WARNING!
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
the work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.

Tightening torque
Transaxle and engine fastening bolt and nut
(a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
3) Tighten drive plate to torque converter bolts. Align bolt hole of drive plate and torque converter then
tighten bolts through torque converter housing lower
plate opening.
Lock drive plate (1) by engaging flat head rod or the
like (2) with drive plate gear.
Tightening torque
Drive plate to torque converter bolt (a): 25 N·m (
2.5 kgf-m, 18.0 lb-ft) 4) Tighten transaxle stiffener bolts to specified torque.
5) Install transaxle housing lower plates (1).
Tightening torque
Transaxle stiffener bolt (a): 55 N·m (5.5 kgf-m,
40 lb-ft)
6) Install starter motor. Tightening torque
Starter motor bolt and nut: 50 N·m (5.0 kgf-m,
36.5 lb-ft)
7) Remount engine with transaxle assembly to vehicle. Refer to “Engine Assembly Removal and Installation
in Section 1D” for its procedure.
3. Wrench 4. Engine oil pan
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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).
1 2
4
3
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-125
Direct Clutch Assembly Disassembly and
Reassembly
S7RS0B5106039
Disassembly1) Remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates.
2) Using special tool and hydraulic press, remove shaft snap ring (1).
Special tool
(A): 09926–98310
CAUTION!
Do not press direct clutch return spring
subassembly in over 0.7 mm (0.027 in.).
Excessive compression may cause damage
to direct clutch return spring subassembly
and/or piston.

3) Remove direct clutch re turn spring assembly (2).
4) Using a finger to block oil hole (1), apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2, 57 –
113 psi) to opposite hole, which will assist in removal
of the clutch piston. 5) Remove outer O-ring (1).
6) Remove inner O-ring (2).
7) Remove input shaft seal rings (1).
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2. Direct clutch piston
1. Input shaft subassembly
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