2000 SUZUKI SWIFT automatic transmission

AUTOMATIC TRANSMISSION (4 A/T) 7B-121
12) Measure 1st & 2nd brake (B1) stroke and clearance in fol-
lowing manner.
Set the dial gauge (1) to 1st & 2nd brake (B1) piston as
shown. Blow compressed air into hole (4) shown in figure.
Then measure the difference as the compressed air is blown
in.
1st & 2nd brake (B1) piston stroke
Standard : 1.79 – 2.01 mm (0.0705 – 0.0791 in.)
Set the dial gauge (1) on the top-most brake disc (5).
Blow compressed air into the hole (4) shown in figure.
Measure the difference. Call this value (A).
If the measured value (s) is (are) out of specification, replace
brake discs, plates and flange.
1st & 2nd brake (B1) disc clearance
Standard : 1.31 – 1.96 mm (0.0516 – 0.0772 in.)
\
13) Install O/D brake (B0) return spring seat (4), return spring (3)
and then retainer (2).
14) While compressing retainer (2), install snap ring (1).
2. Tip of dial gauge on B1 brake piston
3. Air gun
CAUTION:
Position return spring (3) to be centered so that rear
cover not be caught.

7B-122 AUTOMATIC TRANSMISSION (4 A/T)
15) Install thrust needle roller bearing (1) and planetary sun gear
No.2 (2). Turn planetary sun gear No.2 (2) right and left to
match the brake discs and the spline of planetary sun gear
No.2.
16) Install thrust needle roller bearing (3) and planetary set (4).
Turn planetary set (4) right and left to match the gears of the
planetary sun gear No.2 (2) and the gears of the planetary
set (4).
17) Install thrust needle roller bearing (5) and planetary sun gear
No.1 assembly (6). Turn planetary sun gear No.1 assembly
(6) right and left to match the gears of planetary set (4) and
the gears of planetary sun gear No.1 assembly (6).
18) Install O/D brake (B0) discs (1) and plates (2).

AUTOMATIC TRANSMISSION (4 A/T) 7B-123
19) Measure the clearance of O/D brake (B0) in the following
manner.
Blow compressed air into hole (4) shown in figure to activate
1st & 2nd brake (B1) piston, then measure the distance
between the top of O/D brake (B0) plate and the transmis-
sion case – rear cover mating surface.
Call this value (A).
((A) = The value on vernier caliper – width of straight edge )
Measure the distance from top of O/D brake (B0) piston (on
rear cover) to rear cover – transmission case mating surface.
Call this value (B).
Clearance = (A) – (B) + 0.4
O/D brake (B0) clearance
Standard : 0.80 – 1.40 mm (0.0315 – 0.0551 in.)
20) If the obtained value is out of standard value, replace brake
disc and plate.
21) Install O/D brake piston adapter (1) thrust needle roller bear-
ing (2) and direct clutch (C0) assembly (3).
1. Straight edge
2. Vernier caliper
3. Rear cover assembly (with B0 piston)
5. Air gun
6. O/D brake piston adapter

7B-124 AUTOMATIC TRANSMISSION (4 A/T)
22) Install thrust needle roller bearing (3).
23) Install thrust washer (2).
24) Install new gasket to transmission case and install rear cover
(1).
Tightening torque
Rear cover bolts
(a) : 19 N·m (1.9 kg-m, 14.0 lb-ft)
25) Measure clearance between thrust washer and rear cover in
the following manner.
Measure the shaft and play of planetary set (1) with dial
gauge (2).
If the obtained clearance is out of specification, select the
thrust washer from table below and repeat above steps 22) –
24) to obtain the clearance within specification.
Clearance between thrust washer and rear cover
Standard : 0.3 – 0.7 mm (0.012 – 0.028 in.)
Available thrust washer (thickness)
: 1.9 mm (0.075 in.), 2.2 mm (0.087 in.), 2.5 mm (0.098 in.)
or 2.8 mm (0.110 in.)
1. Rear cover
4. Gasket(a)
NOTE:
Install the hook (2) to the location shown in figure.
NOTE:
Make sure that tip of dial gauge is not in contact with
counter drive gear (3).

AUTOMATIC TRANSMISSION (4 A/T) 7B-125
26) Attach parking lock rod (2) to manual shift shaft (1).
27) Install manual shift shaft and washer (3) to transmission
case. Fix manual shift shaft with washer, control shift lever
(4) and two nuts (5).
Apply grease to the washers.
Tightening torque
Control shift lever nuts
(a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
“A” : Grease 99000-25030
28) Install detent spring (1) to transmission case.
Tightening torque
Detent spring bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
29) Install thrust needle roller bearing (2) on counter bearing (3).
30) Install counter driven gear (1).
31) Install parking lock pawl sleeve (1) and oil plate (not shown
in figure).
Tightening torque
Parking lock pawl sleeve bolt
(a) : 19 N·m (1.9 kg-m, 14.0 lb-ft)

7B-126 AUTOMATIC TRANSMISSION (4 A/T)
32) Install parking lock pawl (2).
33) Install parking lock pawl shaft (4), torsional spring (3), and
cover (1), then hold them with 2 bolts.
Tightening torque
Parking lock pawl bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
34) Install reverse brake (B2) plates, discs, flange and cushion
plate in following order :
(1) Cushion plate →
(2) Plate →
(3) Disc →
(4) Plate →
(5)
Disc →
(6) Plate →
(7) Disc →
(8) Plate →
(9) Disc →
(10)
Flange
35) Hold above parts with snap ring.
NOTE:
 Note the direction of cushion plate (1).
 Make sure that the plates are fitted into groove of
transmission case as shown in figure.
2. Brake plate side
3. Transmission case side

AUTOMATIC TRANSMISSION (4 A/T) 7B-127
36) Inspect reverse brake (B2) piston stroke and clearance by
blowing compressed air into hole (4) shown in figure.
Make sure that the obtained piston stroke and clearance sat-
isfy the standard value.
Set dial gauge (1) to the top of reverse brake (B2) flange and
blow compressed air into the hole shown in figure.
Reverse brake disc clearance
Standard : 0.79 – 1.69 mm (0.031 – 0.067 in.)
Set special tool (B) on the tip of dial gauge and place the
other end of special tool on the claw of reverse brake (B2)
piston. Blow compressed air into the hole (4) shown in figure
and measure the value for piston stroke.
Reverse brake piston stroke
Standard : 1.77 – 2.59 mm (0.070 – 0.102 in.)
Special tool
(B) : 09952-06020
37) Apply grease to thrust washers (1) and install them to follow
shaft (2).
“A” : Grease 99000-25030 NOTE:
If clearance and/or piston stroke is out of specification,
disassemble reverse brake (B2) discs and plates, rein-
stall them to satisfy the measured values to standard
value.
2. Tip of dial gauge on the top of B2 brake flange
3. Air gun
[A] : Clearance
[B] : Piston Stroke
NOTE:
When installing thrust washers, make sure that the pro-
trusions of thrust washer do not interfere with the ones
of the other side.

7B-128 AUTOMATIC TRANSMISSION (4 A/T)
38) Install follow shaft (1) to transmission case.
Turn it right and left to match the reverse brake (B2) discs
and the spline of follow shaft.
39) Install thrust needle roller bearing (1) to intermediate shaft
(2).
40) Install intermediate shaft (1) to transmission case.
41) Install rear clutch assembly (1) by turning it right and left to
match the clutch disc of rear clutch assembly and the spline
of intermediate shaft.
42) Install thrust bearing race (2).
“A” : Grease 99000-25030
43) Install front clutch assembly (1) by turning it right and left to
match the clutch of disc clutch assembly and the spline of
follow shaft. NOTE:
When installing follow shaft, do not let the thrust washer
fall off from follow shaft.