001 SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-31
Synchronizer Parts InspectionS7RS0B5206021
Check clearance “a” between synchronizer ring (2) and
gear (1), each chamfered tooth of gear, synchronizer
ring and sleeve, then determine parts replacement.
Clearance “a” between synchronizer ring and gear
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)Put the 2nd gear synchronizer outer ring (1), inner ring
(3) and the cone (2) together and then measure the step
difference between the outer ring and the inner ring. And
also check each chamfered tooth of gear and
synchronizer ring and replace with new one, if
necessary. Also, check gear tooth.
Difference “b” between synchronizer outer ring and
inner ring
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)
Gear Shift Shaft ComponentsS7RS0B5206022
I2RH01520048-01
I2RH01520059-01
5
3
4 6
1
2
8
7
77
(a)
(b)
(a)
(a)
I4RS0A520015-01
1. Low speed gear shift shaft
5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
2. High speed gear shift shaft 6. 5th gear shift fork : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
3. 5th & reverse gear shift shaft 7. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
4. 5th & reverse gear shift guide shaft 8. Shift fork bolt
: Apply thread lock 99000-32110 to bolt thread.

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly. Make sure that all parts are clean.
1) Assemble differential gear and measure thrust play
of differential gear as follows.
Special tool
(A): 09900–20607
(B): 09900–20701
Differential gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
1. Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top
surface of gear (2).
2. Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.
Right side
1. Using similar procedure to the left side, set dial gauge tip to gear (2) shoulder.
2. Move gear up and down by hand and read dial gauge.
2) If thrust play is out of sp ecification, select suitable
thrust washer from among the following available
size, install it and check again that specified gear
play is obtained.
Available thrust washer thickness
3) Drive in new differential pinion shaft pin (2) till the depth from differential case (3) surface is about 1
mm (0.04 in.).
4) Press-fit left bearing (2) using special tool and copper hammer.
Special tool
(A): 09913–76010
5) Support differential assembly (1) as illustrated so as to left bearing is floating , and then press-fit right
bearing (3) using special tools.
Special tool
(A): 09913–76010
(B): 09951–16060
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.90 mm (0.035 in.) 1.10 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.00 mm (0.039 in.)
[A]: Left side
[B]: Right side
I3RH0A520083-01
1
(A)
3
2 (B)
I6RS0C520008-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-35
6) Hold differential assembly with soft jawed vise (3),
install final gear (2) as shown in figure and then
tighten bolts (1) to specified torque.
CAUTION!
Use of any other bolts than specified ones is
prohibited.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS7RS0B5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Leve r and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A520043-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Transaxle oil drain plug 21 2.1 15.5 )
Transaxle oil level / filler plug 21 2.1 15.5 )
Back up light switch 23 2.3 17.0 )
Gear shift guide case bolt 23 2.3 17.0 )
Select lever bracket bolt 23 2.3 17.0 )
Gear shift interlock bolt 23 2.3 17.0 )
5th to reverse interlock guide bolt 23 2.3 17.0 )
Countershaft nut 100 10.0 72.5 )
Shift fork bolt 10 1.0 7.5 )
Side cover bolt 10 1.0 7.5 )
Reverse gear shift lever bolt 23 2.3 17.0 )
Reverse shaft bolt 23 2.3 17.0 )
Transaxle case bolt 23 2.3 17.0 )
Side bearing retainer bolt 23 2.3 17.0 )
Gear shift locating bolt 13 1.3 9.5 )
Left case plate bolt 23 2.3 17.0 )
Oil gutter bolt 10 1.0 7.5 )
Final gear bolt 90 9.0 65.0 )

Downloaded from www.Manualslib.com manuals search engine 5B-36 Manual Transmission/Transaxle:
Special Tools and Equipment
Recommended Service MaterialS7RS0B5208001
NOTE
Required service material is also described in the following.
“Gear Shift Control Leve r and Cable Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Input Shaft and Countershaft Components”
“Gear Shift Shaft Components”
“Differential Components”

Special ToolS7RS0B5208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / ) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / ) / ) / ) /
)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 ) / ) / ) / ) / )
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09913–50121 09913–60910
Oil seal remover Bearing and gear puller (40-
60mm)
))
09913–70123 09913–76010
Bearing installing t ool Bearing installer
) / ) / )) / )
09913–80113 09913–84510
Bearing installer Bearing installer
)) / ) / )
09913–85210 09922–85811
Bearing installer Spring pin remover (4.5 mm)
) / )) / ) / )

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 5C-2 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS7RS0B5304001
Repair Instructions
Clutch Pedal InspectionS7RS0B5306001
Cylinder Push Rod Play “A”1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “A” as shown.
Push rod play
“A”: Max. 3 mm (0.12 in.)
2) If “A” is not within specification, replace master cylinder (3) or pedal arm (2). Clutch Pedal Free Travel “B”
1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“B” in figure.
Clutch pedal free travel
“B”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “B” is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.
Condition Possible cause Correction / Reference Item
Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel
surface Replace disc, clutch cover or flywheel.
Weakened diaphragm spring Replace clutch cover.
Master cylinder piston or seal cup not
returning Replace master cylinder.
Dragging clutch Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Weakened diaphragm spring, or worn
spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle
input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
Clutch vibration Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly on
input shaft bearing retainer Lubricate or replace input shaft bearing
retainer.
Wobbly clutch disc, or poor facing
contact Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel
surface Replace clutch cover or flywheel.
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
Noisy clutch Worn or broken release bearing Replace release bearing.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring
rattling Replace clutch cover.
Grabbing clutch Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-3
Clutch Release Margin “C”1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) dep ressed, slightly push the
shift lever to re verse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by
“C” in figure.
Clutch release margin
“C”: 25 – 55 mm (0.98 – 2.17 in.)
6) If “C” is not within specificat ion, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”. Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS7RS0B5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to reservoir cap.
Air Bleeding of Clutch SystemS7RS0B5306003
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding
operation.
Brake Fluid
Refer to reservoir cap
2) Remove bleeder plug cap from clutch operating cylinder (3). Attach a vinyl tube (1) to bleeder plug
(4), and insert the other end into container (2).
2
1
“A”
3
2
1
3
“B”
“C”
4
5
I4RS0B530001-01
I4RS0A530023-01
3 4 1
2
3
I4RS0A530003-01

Downloaded from www.Manualslib.com manuals search engine 5C-4 Clutch:
3) Depress clutch pedal several times, and then release clutch pedal, push snap ring (2) and pull pipe
connector (1) one notch.
4) When fluid pressure in cylinder is almost depleted, push pipe connector.
5) Repeat this operation until there are no more air bubbles in hydraulic line.
6) When bubbles stop, depress and hold clutch pedal, push pipe connector, and pull snap ring.
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
9) Replenish fluid into reserv oir up to specified level.
10) Check clutch pedal for sponginess. If found spongy, repeat entire procedure of bleeding.Clutch Pedal Position (CPP) Switch Removal
and Installation
S7RS0B5306004
Removal
1) Disconnect connector of C PP switch (1) with ignition
switch OFF.
2) Remove CPP switch (1 ) from pedal bracket.
Installation 1) Instal CPP switch to pedal bracket.
2) Adjust switch position re ferring to “Clutch Pedal
Position (CPP) Switch Inspection and Adjustment”.
3) Connect connector to CPP switch securely.
2
1
I4RS0A530004-01
I4RS0A530023-01
1
I6RS0C530001-02

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-7
Clutch Operating Cylinder Removal and
Installation
S7RS0B5306010
Removal1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe (2) from operating cylinder referring to “Clutch Fluid Pipe Removal and
Installation”.
3) Remove clutch operating cylinder (1).
Installation
Reverse removal procedure for installation noting the
following. • Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch operating cylinder bolt to specified torque.
Tightening torque
Clutch operating cylinder bolt: 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
Clutch Operating Cylinder InspectionS7RS0B5306011
Check operating cylinder for damage and fluid leakage.
If malfunction is found, repl ace clutch operating cylinder.
Clutch Pedal and Clutch Pedal Bracket ComponentsS7RS0B5306012
2
1I4RS0A530010-01
“A”
I4RS0A530011-01
I6RS0C530005-01
1. Clutch pedal bracket 9. Pedal pad
2. Pedal bracket nut 10. Cushion
3. Pedal bracket bolt : Pedal bracket bolt must be tighten after pedal bracket nut. 11. Return spring
: Apply grease 99000-25011 to inside of spring.
4. Pedal shaft bolt 12. Pedal cover plate
5. Pedal bush : Apply grease 9900-25011 to outside of bush. 13. Pedal plate cushion
6. Pedal shaft spacer : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
7. Pedal shaft nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 5C-8 Clutch:
Clutch Cover, Clutch Disc and Flywheel ComponentsS7RS0B5306013
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S7RS0B5306014
Removal1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with specia l tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811
8. Clutch pedal : Apply grease 99000-25011 to outside surface of pin.
(a)
(b)
(b)
A
A
A
12
115
6
A3
A4
710
2
98
1
I4RS0A530013-02
1. Flywheel 9. Clutch disc
2. Flywheel bolt 10. Clutch cover bolt
3. Clutch release shaft seal : Apply grease 99000-25011 to seal lip. 11. Release arm
4. Clutch release shaft No.2 bush : Apply grease 99000-25011 to bush inside. 12. Release arm bolt
5. Clutch release shaft : Apply grease 99000-25011 to the end of release shaft arm. :70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
6. Clutch release shaft No.1 bush : Apply grease 99000-25011 to bush inside. :23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
7. Release bearing : Apply grease 99000-25011 to joint of bearing and release shaft and also bearing inside. Do not reuse.
8. Clutch cover
I4RS0A530014-01