clutch disc SUZUKI SWIFT 2008 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

I2RH0B510252-01
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01

Downloaded from www.Manualslib.com manuals search engine 5A-150 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS7RS0B5106060
CAUTION!
• Automatic transaxle consists of highly precise parts. As even flaw in small part
may cause oil leakage or decrease in
function, check each part carefully before
installation.
• Clean all parts with compressed air. Never use wiping cloths or rags.
• Before assembling new clutch or brake discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before
assembly.
• Use Suzuki Super Grease “C” to retain parts in place.
• Be sure to install thrust bearings and races in correct direction and position.
• Make sure that snap ring ends are not aligned with one of cut outs and are
installed in groove correctly.
• Do not use adhesive cements on gaskets and similar parts.
• Be sure to torque each bolt and nut to specification.

1) Install new manual shift sh aft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.5 – 1.5 mm (0.02 – 0.06 in.) 2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl ro d (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using spring pin remover with 3.5 mm (0.14 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
I2RH0B510258-01
I2RH0B510259-01
I2RH0B510260-01
I2RH0B510261-01

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-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-160 Automatic Transmission/Transaxle:
55) After applying A/T fluid to input shaft front thrust bearing (1), install it to direct clutch assembly (2).
56) Apply A/T fluid to direct clutch assembly (1). Install direct clutch a ssembly while rotating
clockwise and counterclockwise frequently to fit
clutch discs to mating hub.
NOTE
Before installation, align teeth of direct clutch
discs to facilitate installation.

57) Check for correct installation of direct clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
direct clutch assembly, direct clutch hub and reinstall
them properly.
Distance between direct clutch assembly and
mating surface of transaxle case
“a”: 10.4 – 11.4 mm (0.409 – 0.449 in.) 58) Install oil pump assembly
(1) to transaxle case.
Tightening torque
Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
59) Make sure that input shaft (1) turns smoothly.
I2RH0B510308-01
I2RH0B510309-01
“a”
“a”
1
2
I2RH0B510310-01
I2RH0B510311-01
I2RH0B510312-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-3
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS7RS0B5204001
Repair Instructions
Manual Transaxle Oil ChangeS7RS0B5206001
1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil. 5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Pour new specified oil unt il oil level reaches bottom
of oil filler plug hole (3) as shown in figure.NOTE
It is highly recommended to use API GL-4
75W-90 gear oil.

Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Manual transaxle oil capacity
Reference: 2.0 liters (4.2/3.5 US/Imp. pt)
Condition Possible cause Correction / Reference Item
Gears slipping out of
mesh Worn shift fork shaft
Replace.
Worn shift fork or synchronizer sleeve Replace.
Weak or damaged locating springs Replace.
Worn bearings on input shaft or
countershaft Replace.
Worn chamfered tooth on sleeve and
gear Replace sleeve and gear.
Hard shifting Maladjusted gear select control cable Adjust.
Inadequate or insufficient lubricant Replenish.
Improper clutch pedal free travel Replace clutch master cylinder or clutch pedal
arm.
Distorted or broken clutch disc Replace.
Damaged clutch pressure plate Replace clutch cover.
Worn synchronizer ring Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve or gear.
Worn gear shift / select control cables
joint Replace.
Distorted shift shaft Replace.
Worn gear shift / select control cables Replace.
Noise Inadequate or insufficient lubricant Replenish.
Damaged or worn bearing(s) Replace.
Damaged or worn gear(s) Replace.
Damaged or worn synchronizer parts Replace.

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Manual Transaxle Unit Dismounting and
Remounting
S7RS0B5206009
Dismounting1) Drain coolant and transaxle oil.
2) Remove coolant reservoir with reservoir hose.
3) Remove battery and tray.
4) Remove air cleaner case and resonator.
5) Disconnect gear shift and gear select control cables (1) while pressing claws (2) of clip (3).
6) Disconnect back up light switch coupler and undo wiring harness clamps.
7) Remove ground cable from transaxle.
8) Remove clutch operating cylinder with fluid hose from transaxle.
9) Remove water inlet No.2 pipe from transaxle.
10) Remove starting motor re ferring to “Starting Motor
Dismounting and Remounting in Section 1I”.
11) Remove transaxle to engine bolts (1) of upper side. 12) Support engine using supporting device (1).
CAUTION!
Do not apply supporting device to projection
part A. If do so, it may be deformed.

13) Remove front drive shafts and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
14) Remove exhaust No.2 pipe referring to “Exhaust Pipe and Muffler Removal a nd Installation in Section
1K”.
15) Remove clutch housing lower plate (1).
1
2
3
I7RS0A521003-01
1
1
I4RS0A520018-01
1
A
I4RS0A520019-01
1I4RS0A520020-01

Downloaded from www.Manualslib.com manuals search engine 5B-10 Manual Transmission/Transaxle:
16) Remove engine under covers.
17) Support transaxle with transmission jack.
18) Remove transaxle to engine bolts and nut of lower side.
19) Remove engine left mounting (1) with bracket (2).
20) Remove engine rear mounting bracket bolts (1).
21) Remove other attached parts from transaxle, if any.
22) Pull transaxle so as to disconnect input shaft from clutch disc, and then lower it. Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer when installing it into differential gear.

Reverse dismounting procedure for remounting noting
the following.
• Tighten each bolts and nuts to specified torque referring to “Manual Transaxle Unit Components”.
• Set each clamp for wiring securely.
• Fill transaxle oil referring to “Manual Transaxle Oil
Change”.
• Fill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
• Install hook (1) and ground cable (2) at specified position as shown in figure.
• Connect battery and check function of engine, clutch
and transaxle.
1
2
I4RS0A520021-01
1
I4RS0A520022-01
3. Transaxle side cover 4. Transaxle left case
90
1
2 3
4
I4RS0A520023-01

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.