2000 SUZUKI SWIFT shaft

CLUTCH 7C-13
3) Apply grease to No.2 bush (1) inside and press-fit it by using
the same special tool as in removal.
“A” : Grease 99000-25010
Special tool
(C) : 09922-46010
4) Coat grease to shaft seal (2) lip and then install it till it is flush
with case surface. Use special tool for this installation and
face seal lip downward (inside).
“A” : Grease 99000-25010
Special tool
(D) : 09925-98221
5) Caulk seal at A by using caulking tool and hammer.
6) Hook return spring.
7) Apply grease to release bearing (1) inside and release shaft
arm (2), then set bearing.
“A” : Grease 99000-25010
8) Apply small amount of grease to input shaft (3) spline (0.3 g)
and front end (0.15 g) as well.
“B” : Grease 99000-25210
9) Set release lever to release shaft aligning their punch marks
(1), then tighten bolt.
Tightening torque
Release lever bolt (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft)

7C-14 CLUTCH
TIGHTENING TORQUE SPECIFICATION
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
Fastening partTightening torque
Nm kg-m lb-ft
Flywheel bolts 70 7.0 50.5
Clutch cover bolts 23 2.3 16.5
Release lever bolt 23 2.3 16.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Cable end hook and joint pin.
Release shaft bushes and seal.
Release shaft arm.
Release bearing inside.
SUZUKI SUPER GREASE I
(99000-25210)Input shaft spline and front end.
09921-26020 09922-46010 09923-36320 09923-46020
Bearing remover Bush remover Clutch center guide Joint pipe
09923-46030 09924-17810 09925-98210 09925-98221
Joint pipe Flywheel holder Input shaft bearing
installerBearing installer

CLUTCH 7C-15
09930-30104
Sliding shaft

TRANSFER 7D-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7E
7F
7D
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7D
TRANSFER
CONTENTS
GENERAL DESCRIPTION ...............................7D-2
DIAGNOSIS ......................................................7D-2
ON-VEHICLE SERVICE ...................................7D-3
UNIT REPAIR OVERHAUL ..............................7D-4
UNIT DISMOUNTING ...................................7D-5
UNIT DISASSEMBLY ...................................7D-6
TRANSFER ASSEMBLY...........................7D-6
REDUCTION DRIVEN GEAR ...................7D-7
INTERMEDIATE SHAFT ...........................7D-8
TRANSFER OUTPUT RETAINER ............7D-9
COMPONENT INSPECTION ......................7D-10
UNIT ASSEMBLY .......................................7D-10REDUCTION DRIVEN GEAR ................. 7D-10
BEVEL GEAR SHIM ............................... 7D-11
TRANSFER OUTPUT RETAINER .......... 7D-12
RIGHT CASE .......................................... 7D-16
LEFT CASE............................................. 7D-17
TRANSFER ASSEMBLY ........................ 7D-17
BEVEL GEAR BACK LASH .................... 7D-18
UNIT INSTALLATION ................................. 7D-20
TIGHTENING TORQUE SPECIFICATION..... 7D-22
REQUIRED SERVICE MATERIAL................. 7D-22
SPECIAL TOOL ............................................. 7D-22

7D-2 TRANSFER
GENERAL DESCRIPTION
The transfer consists of parts as shown in figure.
DIAGNOSIS
1. Intermediate shaft 6. Shim 11. Transfer output retainer
2. Left case 7. Reduction driven gear 12. Flange
3. Reduction drive gear 8. Bevel gear✱
:Forward
4. Circlip 9. Bevel pinion shaft
5. Right case 10. Pinion shaft spacer
Condition Possible Cause Correction
Noise
Inadequate or insufficient lubricant Replenish.
Damaged or worn bearing(s) Replace.
Damaged or worn gear(s) Replace.
Damaged or worn chamfered tooth on sleeve or
gearReplace.
Preload of taper roller bearing is reduced Adjust.

TRANSFER 7D-3
ON-VEHICLE SERVICE
OIL CHANGE
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 or repair it.
3) Drain old oil, tighten drain plug (3) after applying sealant to
its thread and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
“A” : Sealant 99000-31230
Tightening torque
Transfer oil drain plug (a) : 21 N·m (2.1 kg-m, 15.5 lb-ft)
Transfer gear oil
:Hypoid gear oil API GL-5
For oil viscosity, refer to the chart.
Oil Capacity
: 0.5 liters (1.1/0.9 US/lmp. pt)
4) Torque level/filler plug (4) as specified below after applying
sealant to its thread.
“A” : Sealant 99000-31230
Tightening torque
Transfer oil level / filler plug
(b) : 21 N·m (2.1 kg-m, 15.5 lb-ft) NOTE:
 It is highly recommended to use SAE 80W-90 Hypoid
gear oil API GL-5.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.
1. Transfer
2. Drive shaft

7D-4 TRANSFER
UNIT REPAIR OVERHAUL
1. Transfer left case 11. Bevel gear shim 21. Driven gear bearing
2. Transfer right case 12. Bevel gear (Hypoid gear) 22. Reduction drive gear bearing
3. Transfer output retainer 13. Bevel pinion shaft (Hypoid gear) 23. Flange nut
: After tightening nut so as rotation torque
of bevel pinion shaft to be in specified
value, caulk nut securely.
4. O-ring
: Apply grease 99000-25010 to all
around surface14. Reduction driven gear 24. Stiffener
5. Bevel pinion shim 15. Flange 25. Intermediate right bearing
6. Drain plug
: Apply sealant 99000-31230 to all
around thread part of drain plug16. Pinion shaft spacer Do not reuse.
7. Level plug
: Apply sealant 99000-31230 to all
around thread part of level plug17. Reduction drive gear Tightening torque
8. Intermediate shaft 18. Circlip Apply transfer oil.
9. Oil seal
: Apply SUZUKI SUPER GREASE A
99000-25010 to oil seal lip.19. Snap ring
10. Pinion shaft bearing 20. Bevel gear nut
: After tightening nut to specified
torque, caulk nut securely

TRANSFER 7D-5
UNIT DISMOUNTING
1) Disconnect negative cable at battery.
2) Hoist vehicle and remove wheels.
3) Drain transmission oil.
4) Remove exhaust No.1 pipe (1).
5) Remove propeller shaft.
6) Remove right side drive shaft (1) refer to Section 4A.
7) Remove Stiffener (3).
8) With transmission assembly held on jack, remove rear
mounting bolts (1).
9) Remove transfer mounting bolts and draw out transfer
assembly from transmission assembly.
2. Exhaust No.2 pipe
12
1
1. Transfer
2. Transmission
1