Matic SUZUKI SWIFT 2008 2.G Service Owner's Guide
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2008, Model line: SWIFT, Model: SUZUKI SWIFT 2008 2.GPages: 1496, PDF Size: 34.44 MB
Page 641 of 1496

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3 A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
Brake Interlock System Construction .................. 5A-8
A/T Diagnosis General Description ..................... 5A-8
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10 Transmission Control  Module (TCM) Wiring 
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Locatio n ......................................... 5A-13
Electronic Shift Cont rol System Components 
Location .......................................................... 5A-13
Diagnostic Information and Procedures .......... 5A-15 A/T System Check ............................................ 5A-15
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp  (MIL) Check .......... 5A-18
Transmission Warning Ligh t Check .................. 5A-18
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-20
DTC Clearance ................................................. 5A-20
Fail-Safe Table ................ .................................. 5A-21
Scan Tool Data ................................................. 5A-23
A/T Basic Check ............................................... 5A-26
Road Test ......................................................... 5A-27
Manual Road Test ........... .................................. 5A-29
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-30
Time Lag Test ................................................... 5A-31
Line Pressure Test .......... .................................. 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ..... .............................. 5A-34 No Gear Shift to 4th gear .................................. 5A-41
No Lock-Up Occurs ........................................... 5A-42
Transmission Warning Light Circuit Check – 
Light Does Not Come “ON” at Ignition Switch 
ON ................................................................... 5A-43
Transmission Warning Light Circuit Check –  Light Remains “ON” at Ignition Switch ON ...... 5A-43
DTC P0602: Control Module Programming  Error ................................................................ 5A-44
DTC P0705: Transmission Range Sensor  Circuit Malfunction (PRNDL input) .................. 5A-44
DTC P0707: Transmission Range Sensor  Circuit Low ...................................................... 5A-46
DTC P0712: Transmission Fluid Temperature  Sensor “A” Circuit Low ... ................................. 5A-48
DTC P0713: Transmission Fluid Temperature  Sensor “A” Circuit High .. ................................. 5A-49
DTC P0717: Input / Turbine Speed Sensor “A”  Circuit Malfunction........................................... 5A-51
DTC P0722: Output Speed Sensor Circuit No  Signal .............................................................. 5A-52
DTC P0787: Shift / Timing Solenoid Low .......... 5A-54
DTC P0788: Shift / Timing Solenoid High ......... 5A-56
DTC P0961: Pressure  Control Solenoid “A” 
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure  Control Solenoid “A” 
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure  Control Solenoid “A” 
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid “A”  Control Circuit Low / Shift Solenoid “B” 
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid “A” / Shift  Solenoid “B” Control Circuit  High .................... 5A-66
DTC P1702: Internal Co ntrol Module Memory 
Check Sum Error............................................. 5A-68
DTC P1703: Can Invalid Data - TCM ................ 5A-68
DTC P1723: Range Select Switch  Malfunction ...................................................... 5A-69
DTC P1774: CAN Communication Bus Off ....... 5A-71
DTC P1777: TCM Lost Communication with  ECM (Reception Error).................................... 5A-73
DTC P1778: TCM Lost Communication with  BCM (Reception Error).................................... 5A-74  
Page 642 of 1496

Downloaded from www.Manualslib.com manuals search engine 5-ii Table of Contents
DTC P1878: Torque Converter Clutch Shudder .......................................................... 5A-75
DTC P2762: Torque Converter Clutch (TCC)  Pressure Control Sole noid Control Circuit 
Range /Performance ....................................... 5A-76
DTC P2763: Torque Converter Clutch  Pressure Control Sole noid Control Circuit 
High ................................................................. 5A-78
DTC P2764: Torque Converter Clutch Circuit  Pressure Control Sole noid Control Circuit 
Low ................................................................. 5A-80
Inspection of TCM and Its Circuits .................... 5A-82
TCM Power and Ground Circuit Check ............. 5A-86
Brake Interlock System Inspection .................... 5A-87
Repair Instructions ........... .................................5A-88
Learning Control Initializat ion ............................ 5A-88
A/T Fluid Level Check ....................................... 5A-89
A/T Fluid Change .............................................. 5A-90
Select Lever Components ... .............................. 5A-90
Select Lever Assembly Removal and  Installation ....................................................... 5A-90
Select Lever Knob Installa tion........................... 5A-90
Select Lever Inspection .... ................................. 5A-91
“3” Position Switch Inspec tion ........................... 5A-91
Shift Lock Solenoid Inspec tion .......................... 5A-91
Shift Lock Solenoid Replacement ..................... 5A-91
Select Cable Components ................................ 5A-92
Select Cable Removal and Installation ............. 5A-92
Select Cable Adjustment ................................... 5A-93
Key Interlock Cable Removal and Installation... 5A-93
Transmission Range Sensor (Shift Switch)  Inspection and Adjustment .............................. 5A-95
Output Shaft Speed Sensor Removal and  Installation ....................................................... 5A-96
Output Shaft Speed Sensor  Inspection ............. 5A-96
Input Shaft Speed Sensor Removal and  Installation ....................................................... 5A-96
Input Shaft Speed Sensor Inspection................ 5A-97
Transmission Fluid Temperature Sensor  Removal and Installation ................................. 5A-97
Transmission Fluid Temperature Sensor  Inspection ........................................................ 5A-98
Solenoid Valves (Shift Solenoid Valves and  Timing Solenoid Valve) Removal and 
Installation ....................................................... 5A-98
Solenoid Valves (Shift Solenoid Valves, and  Timing Solenoid Valve) Inspection .................. 5A-99
Pressure Control Soleno id Valves (Pressure 
Control Solenoid and  TCC Pressure Control 
Solenoid) Removal and Inst allation .............. 5A-101
Pressure Control Solenoid Valve Inspection ... 5A-101
Transmission Control Module (TCM)  Removal and Installation ............................... 5A-102
A/T Relay Inspection ....................................... 5A-103
Differential Side Oil Seal  Replacement ........... 5A-103
A/T Fluid Cooler Hoses Replacement ............. 5A-104
Automatic Transaxle Unit  Components........... 5A-105
Automatic Transaxle Unit Dismounting and  Remounting ................................................... 5A-106
Automatic Transaxle Asse mbly Components . 5A-108 Automatic Transaxle Unit
 Disassembly........... 5A-110
Oil Pump Assembly Components ................... 5A-121
Oil Pump Assembly Disassembly and  Reassembly .................................................. 5A-122
Oil Pump Assembly Inspection ....................... 5A-122
Direct Clutch Assembly Components.............. 5A-124
Direct Clutch Assembly Preliminary Check ..... 5A-124
Direct Clutch Assembly Disassembly and  Reassembly .................................................. 5A-125
Direct Clutch Assembly Inspection.................. 5A-127
Forward and Reverse Clutch Assembly  Components .................................................. 5A-128
Forward and Reverse Clutch Assembly  Preliminary Check ......................................... 5A-129
Forward and Reverse Clutch Assembly  Disassembly and Reassembly ...................... 5A-129
Forward and Reverse Clutch Assembly  Inspection ...................................................... 5A-133
2nd Brake Piston Assembly Components ....... 5A-134
2nd Brake Piston Assembly Disassembly and  Reassembly .................................................. 5A-134
Transaxle Rear Cover (O/D and 2nd Coast  Brake Piston) Assembly Components........... 5A-135
Transaxle Rear Cover (O/D and 2nd Coast  Brake Piston) Assembly Disassembly and 
Reassembly .................................................. 5A-136
Transaxle Rear Cover (O/D and 2nd Coast  Brake Piston) Assembly Inspection............... 5A-137
Countershaft Assembly Co mponents.............. 5A-138
Countershaft Assembly Disassembly and  Reassembly .................................................. 5A-138
Valve Body Assembly Components ................ 5A-139
Valve Body Assembly Disassembly and  Reassembly .................................................. 5A-140
Differential Assembly Components ................. 5A-141
Differential Assembly Disassembly and  Reassembly .................................................. 5A-142
Differential Assembly Inspection ..................... 5A-143
Torque Converter Housing Disassembly and  Reassembly .................................................. 5A-144
Transaxle Case Disassembly and  Reassembly .................................................. 5A-146
Automatic Transaxle Unit Inspection and  Adjus
 tment .................................................... 5A-147
Automatic Transaxle Unit Assembly ............... 5A-150
Specifications .................. .................................5A-167
Tightening Torque Specifications .................... 5A-167
Special Tools and Equipmen t .........................5A-168
Recommended Service Material ..................... 5A-168
Special Tool .................................................... 5A-168
Manual Transmission/Tr ansaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction and Servicing .... 5B-1
Diagnostic Information and Procedures ............5B-3 Manual Transaxle Symptom  Diagnosis............... 5B-3
Repair Instructions ............ ..................................5B-3
Manual Transaxle Oil Change............................. 5B-3
Differential Side Oil Seal Replacement ............... 5B-4  
Page 645 of 1496

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle:  5A-1
Transmission / Transaxle
Automatic Transmission/Transaxle
Precautions
Precautions in Diagnosing TroubleS7RS0B5100001
• Do not disconnect couplers from TCM, battery cable from battery, TCM ground wire harness from engine or 
main fuse before checking  the diagnostic information 
(DTC, freeze frame data, etc.) stored in TCM memory. 
Such disconnection will clea r memorized information 
in TCM memory.
• Diagnostic information stored in TCM memory can be  cleared as well as checked by using SUZUKI scan 
tool or generic scan tool. Before using scan tool, read 
its Operator’s (Instruction) Manual carefully to have 
good understanding as to what functions are available 
and how to use it.
It is indistinguishable wh ich module turns on MIL 
because not only ECM but also TCM turns on MIL.
Therefore, check both ECM and TCM for DTC when 
MIL lights on.
When checking TCM for DTC, keep in mind that DTC 
is displayed on the scan tool as follows depending on 
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– Generic scan tool displays DTC detected by each  of ECM and TCM simultaneously.
• Using SUZUKI scan tool the diagnostic information  stored in TCM memory can be checked and cleared 
as well. Before its use, be  sure to read Operator’s 
Manual supplied with it carefully to have good 
understanding of its functions and usage.
• Be sure to read “Precautions for Electrical Circuit  Service in Section 00” befo re inspection and observe 
what is written there.
• TCM replacement
– When substituting a known-good TCM, check that all relays and actuators have resistance of 
specified value.
Neglecting this check may result in damage to good 
TCM.
• Communication of ECUs , ECM, TCM, ABS control 
module, keyless start control module and BCM is 
established by CAN (Controller Area Network). 
Therefore, handle CAN communication line with care 
referring to “Precaution for CAN Communication 
System in Section 00”.
Precautions for Disassembly and ReassemblyS7RS0B5100002
When repairing automatic transaxle, it is necessary to 
conduct the on-vehicle test to investigate where the 
cause of the trouble lies first.
Then whether overhaul should be done or not is 
determined. If the transaxle is disassembled without 
such preliminary procedure, not only the cause of the 
trouble would be unknown, but also a secondary trouble 
may occur and often time would be wasted.
As the automatic transaxle consists of high precision 
component, the following cautions should be strictly 
observed when handling its parts in disassembly and 
reassembly.
• Disassembling valve body  assembly is prohibited 
essentially. However, a few parts can be 
disassembled. When disassembling valve body 
component parts, confirm whether their parts are 
allowed to disassemble or not referring to “Valve Body 
Assembly Disassembly and Reassembly”.
• When component part of forward clutch, direct clutch,  2nd brake and/or O/D and 2nd coast brake, namely 
clutch disc, brake disc, retaining plate and/or 
separator plate, have been replaced, all learned 
contents, which have been stored in TCM memory by 
executing learning control, should be initialized 
referring to “Learning Control Initialization”.
• Make sure to wash dirt off from the transaxle so that  no such dirt will enter  the transaxle during 
dismounting and remounting.
• Select a clean place free from dust and dirt for  overhauling.
• Place a rubber mat on the work bench to protect parts  from damage.
• Work gloves or shop cloth should not be used. (Use a  nylon cloth or a paper towel.)
• When separating the case joint, do not pry with a  screwdriver or such but tap with a plastic hammer 
lightly.
• Make sure to wash dirt off from the transaxle so that  no such dirt will enter  the transaxle during 
disassembly and reassembly.
• Wash the disassembled parts in ATF (Automatic  Transaxle Fluid) or kerosene  (using care not to allow 
ATF or kerosene to get on your face, etc.) and confirm 
that each fluid passage is not clogged by blowing air 
into it. But use kerosene to wash the discs, resin 
washers and rubber parts.
• Replace each gasket, oil seal and O-ring with a new  one.
• Apply ATF to sliding or  rotating parts before 
reassembly.  
Page 646 of 1496

Downloaded from www.Manualslib.com manuals search engine 5A-2 Automatic Transmission/Transaxle: 
CAUTION! 
• Keep component parts in group for each subassembly and avoid mixing them up.
• Clean all parts with cleaning solvent  thoroughly and air dry them.
• Use kerosene or automatic transaxle fluid  as cleaning solvent.
• Do not use wiping cloths or rags to clean  or dry parts.
• All oil passages should be blown out and  checked to make sure that they are not 
obstructed.
• Keep face and eyes away from solvent  spray while air blowing parts.
• Check mating surface for irregularities and  remove them, if any, and clean it again.
• Soak new clutch discs and brake discs in  transaxle fluid for at least 2 hours before 
assembly.
• Replace all gaskets and O-ring with new  ones.
• Apply automatic transaxle fluid to all O- rings.
• When installing seal ring, be careful so that  it is not expanded excessively, extruded or 
caught.
• Replace oil seals that are removed and  apply grease to their lips.
• Before installing, be sure to apply  automatic transaxle fluid to sliding, rolling 
and thrusting surface of all component 
part. Also after installation, make sure to 
check each part for proper operation.
• Always use torque wrench when  tightening bolts.
 
• A new discs should be soaked in ATF at least 2 hours before use.
Part Inspection and Correction Table Part Inspect for Correction
Casted part, 
machined part Small flaw, burr
Remove with oil 
stone.
Deep or grooved 
flaw Replace part.
Clogged fluid 
passage Clean with air or 
wire.
Flaw on installing 
surface, residual 
gasket Remove with oil 
stone or replace 
part.
Crack Replace part.
Bearing Unsmooth rotation Replace.
Streak, pitting, flaw, 
crack
Replace.
Bushing, thrust 
washer Flaw, burr, wear, 
burning
Replace.
Oil seal, gasket Flawed or 
hardened seal ring
Replace.
Worn seal ring on 
its periphery or side Replace.
Piston seal ring, oil 
seal, gasket, etc. Replace.
Gear Flaw, burr Replace.
Worn gear tooth Replace.
Splined part Burr, flaw, torsion Correct with oil 
stone or replace.
Snap ring Wear, flaw, 
distortion
Replace.
No interference Replace.
Thread Burr Replace.
Damage Replace.
Sp rin g Settling, sign of 
burning Replace.
Friction plate Wear, burning, 
distortion, 
damaged claw Replace.
Separator plate, 
retaining plate Wear, burning, 
distortion, 
damaged claw
Replace.
Sealing surface 
(where lip 
contacts) Flaw, rough 
surface, stepped 
wear, foreign 
material
Replace.  
Page 647 of 1496

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle:  5A-3
General Description
A/T DescriptionS7RS0B5101001
This automatic transaxle is electronic control full automatic transaxle with forward 4-speed and reverse 1-speed. 
The torque converter is a 3-element, 1-step and 2-phase type  and is equipped with an automatically controlled lock-up 
mechanism.
The gear change device consists of a ravigneau type planet ary gear unit, 3 multiple disc type clutches, 3 multiple disc 
type brakes and 2 one-way clutches.
The hydraulic pressure control device consists of a valve body assembly, pressure control solenoid valve (linear 
solenoid), 2 shift solenoid va lves, TCC pressure control solenoid valve (lin ear solenoid) and a timing solenoid valve. 
Optimum line pressure complying with engine torque is produced by the pressure control solenoid valve in 
dependence upon control signal from transmission control  module (TCM). This makes it possible to control the line 
pressure with high accuracy in accordance with the engine  power and running conditions to achieve smooth shifting 
characteristics and high efficiency.
A clutch-to-clutch control system is prov ided for shifting between 3rd gear and 4th gear. This clutch-to-clutch control 
system is made to function optimally , so that hydraulic pressure controls such as shown below are conducted.
• When upshifting from 3rd gear to 4th gear, to adjust the  drain hydraulic pressure at releasing the forward clutch, a 
timing solenoid valve is used to switch a hydraulic  passage with an orifice to another during shifting.
• When downshifting from 4th gear to 3rd gear, to adjust the line pressure applied to the forward clutch at engaging  the forward clutch, a timing solenoid valve is used to s witch a hydraulic passage with an orifice to another during 
shifting.
• When upshifting from 3rd gear to 4th gear with engine throttle opened, to optimize the line pressure applied to the  forward clutch at releasing the forward clutch, the learning  control is processed to compensate the switching timing 
of the timing solenoid at every shifting.
• When downshifting from 4th gear to 3rd gear with engine  throttle opened, to optimize the line pressure applied to 
the forward clutch at engaging the forw ard clutch, the learning control is processed to compensate the line pressure 
at every shifting.
Employing the ravigneau type planetary gear unit and this  clutch-to-clutch control system greatly simplifies the 
construction to make possible a  lightweight and compact transaxle.
A line pressure learning control is conducted to provide opti mum shifting time at every upshifting with engine throttle 
opened. If long upshifting time is detected, the subsequent line pressure applied during upshifting is intensified. On the 
contrary, if short upshifting time is detected, the subs equent line pressure applied during upshifting is weakened.
Slip controlled lock-up function
Even at a lower speed than when the TCC gets engaged completely, control over the TCC pressure control solenoid 
works to cause the TCC to slip (be engaged slightly), ther eby improving the transmission efficiency. While such slip 
control is being executed, the oil pressure applied to the  TCC is controlled by the TCC pressure control solenoid so 
that the difference between the engine speed and the  input shaft speed becomes close to the specified value.
Also, during deceleration, the TCC is made to slip (be enga ged slightly) to raise the engine speed and enlarge the fuel 
cut operation range so that better fuel consumption is achieved.
Due to this reason, it is absolutely necessary for the automati c transmission to use ATF suitable for slip control. Use of 
any fluid other than the specified ATF may cause j uddering or some other faulty condition to occur.  
Page 648 of 1496

Downloaded from www.Manualslib.com manuals search engine 5A-4 Automatic Transmission/Transaxle: 
1
2
3
4567891011121314151617
18 19 20 21 22 23
24 25
26
27
28I3RM0B510001-01
1. Drive plate 11. 1st and reverse brake 21. Rear sun gear
2. Torque converter clutch (TCC) 12. Ring gear22. Front sun gear
3. Torque converter 13. Long planet pinion23. Short planet pinion
4. Input shaft 14. One-way No.2 clutch 24. Countershaft
5. Oil pump 15. 2nd brake25. Reduction driven gear
6. Direct clutch drum (double as sensor ro tor for input shaft speed sensor) 16. One-way No.1 clutch 26. Differential case assembly
7. Direct clutch 17. O/D and 2nd coast brake 27. Final gear
8. Parking lock gear 18. Intermediate shaft28.Output shaft speed sensor drive gear
9. Reduction drive gear 19. Forward clutch
10. Planet carrier 20. Reverse clutch  
Page 649 of 1496

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle:  5A-5
SpecificationsItem Specifications
Torque converter Ty p e  
Stall torque ratio 3-element, 1-step, 2-phase type (with TCC (lock-up) 
mechanism)
2.0 – 2.2
Oil pump Ty p e
Drive system Internal involute gear type oil pump (non crescent type)
Engine driven
Gear change 
device Type Forward 4-step, reverse 1-step planetary gear type
Shift position
“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range 
Forward 1st 
↔ 2nd  ↔ 3rd  ↔ 4th automatic gear 
change
“3” range Forward 1st 
↔ 2nd  ↔ 3rd  ← 4th automatic gear 
change
“2” range Forward 1st  ↔ 2nd  ← 3rd automatic gear change
“L” range Forward 1st 
← 2nd ←  3rd reduction, and fixed at 1st 
gear
Gear 
ratio 1st  2.875 Number of teeth Front sun gear: 24
2nd  1.568 Rear sun gear: 30
3rd  1.000 Long planet pinion: 20
4th (overdrive gear) 0.697 Short planet pinion: 19
Reverse (reverse gear) 2.300 Ring gear: 69
Control elements Wet type multiple-disc clutch... 3 sets
Wet type multiple-d
isc brake... 3 sets
One-way clutch... 2 sets
Reduction gear ratio 1.023
Final gear reduction ratio 4.277
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used SUZUKI ATF 3317 or Mobil ATF 3309  
Page 650 of 1496

Downloaded from www.Manualslib.com manuals search engine 5A-6 Automatic Transmission/Transaxle: 
Clutch / Brake / Planetary Gear Function of Automatic TransaxleS7RS0B5101002
Functions
12
4
3 5
6
7
89
10 11
12 13
14 15 16
17
18
19
I4RS0A510001-01
1. Input shaft and intermediate shaft 6. Long planet pi nion 11. O/D and 2nd coast brake 16. Rear sun gear
2. Direct clutch 7. 1st and reverse brak e 12. Reverse clutch 17. Final drive gear
3. Reduction drive gear 8. One-way No.2 clutch 13. Forward clutch 18. Reduction driven gear
4. Planet carrier 9. 2nd brake 14. Ring gear 19. Final driven gear
5. Short planet pinion 10. One-way No.1 clutch 15. Front sun gear
Part name Function
Forward clutch Meshes intermediate shaft and front sun gear Direct clutch Meshes input shaft and planet carrier
Reverse clutch Meshes intermediate shaft and rear sun gear
O/D and 2nd coast brake Fixes rear sun gear 2nd brake Fixes rear sun gear
1st and reverse brake Fixes planet carrier One-way No.1 clutch Prevents rear sun gear from turning counterclockwise
One-way No.2 clutch Prevents planet ca rrier from turning counterclockwise