2000 SUZUKI SWIFT clutch cable

AUTOMATIC TRANSMISSION (4 A/T) 7B-29
P0741 29Torque converter clutch (lock-up)
solenoid performance or stuck off2 driving
cyclesNot
applicable
P0720 31Output shaft speed sensor circuit
malfunction1 driving
cycleNot
applicable
P170032
Throttle position signal input mal-
function1 driving
cycleNot
applicable
33
P0705 34Transmission range sensor circuit
malfunction1 driving
cycleNot
applicable
P0725 35Engine speed input circuit malfunc-
tion2 driving
cyclesNot
applicable
P071036
Transmission temperature sensor
circuit malfunction2 driving
cyclesNot
applicable
38
P1709 51Engine coolant temperature signal
circuit1 driving
cycleNot
applicable
P0702
52Transmission control system elec-
trical1 driving
cycleNot
applicable
P1702 Internal malfunction of TCMDTC NO.
“O/D OFF” Lamp
Flashing Pattern of DTC
(Not using scan tool)DETECTING ITEMSMIL
Using
scan toolNot using
scan toolVehicle
equipped
with
immobi-
lizer indi-
cator lampVehicle
equipped
without
immobi-
lizer indi-
cator lamp

7B-70 AUTOMATIC TRANSMISSION (4 A/T)
LEARNING CONTROL INITIALIZATION
When one or more operations such as shown below are per-
formed, all learned contents which are stored in TCM memory
should be erased after the operations.
Replacing transmission with new or used one.
Repairing transmission partially by replacing any brake com-
ponent parts with new and/or used brake disc(s), plate(s)
and/or flange.
Repairing transmission partially by replacing any clutch com-
ponent parts with new and/or used clutch disc(s), plate(s)
and/or flange.
Replacing TCM with used one.
1) Turn ignition switch ON, leaving engine OFF.
2) Using service wire, connect diagnosis switch terminal (2)
with ground terminal (3) of monitor connector No.2 (1).
3) Shift selector lever from “D” range to “2” range 3 times
repeatedly within 10 seconds with diagnosis switch terminal
(2) kept on connecting with ground.
4) Check DTC referring to “DTC CHECK” in this section and
confirm that only DTC No.12 is displayed.
If not, repeat Step 1) to Step 3) and check again.
BRAKE INTERLOCK SYSTEM (IF EQUIPPED)
SHIFT LOCK SOLENOID CONTROL
This system consists of shift lock solenoid control system and
interlock cable control system.
The shift lock solenoid control system is so designed that the
selector lever can not be shifted from “P” range position unless
ignition switch is turned ON and the brake pedal is depressed.
And interlock cable control system is so designed that select lever
cannot be shifted from “P” range position unless ignition switch is
turned to “ACC” or “ON” position. Also, ignition key cannot be
pulled out of key slot unless selector lever is in “P” range. NOTE:
 “O/D OFF” lamp lights during initializing.
 Diagnostic trouble code(s) (DTC(s)) also are erased by
performing this initializing procedure.
 After initializing is achieved, DTC No.12 is stored in
TCM. If initializing is failed, DTC No.52 is stored in
TCM.
1
2
3

CLUTCH 7C-1
6F1
6F2
6G
6H
6K
7A1
7B1
7C1
7D
7E
7C
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7C
CLUTCH
CONTENTS
GENERAL DESCRIPTION .............................. 7C-2
DIAGNOSIS ..................................................... 7C-3
ON-VEHICLE SERVICE .................................. 7C-4
CLUTCH CABLE .......................................... 7C-4
CLUTCH PEDAL AND CLUTCH PEDAL
BRACKET .................................................... 7C-6
CLUTCH PEDAL HEIGHT ....................... 7C-7
CLUTCH PEDAL FREE TRAVEL ............ 7C-7UNIT REPAIR OVERHAUL ............................. 7C-8
CLUTCH COVER, CLUTCH DISC AND
FLYWHEEL.................................................. 7C-8
CLUTCH RELEASE SYSTEM ................... 7C-11
TIGHTENING TORQUE SPECIFICATION.... 7C-14
REQUIRED SERVICE MATERIAL................ 7C-14
SPECIAL TOOL ............................................ 7C-14

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

CLUTCH 7C-3
DIAGNOSIS
Condition Possible Cause Correction
Slipping
Improper clutch pedal free travel Adjust free travel.
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.
Rusted clutch cable Replace cable.
Dragging clutch
Improper clutch pedal free travel Adjust free travel.
Weakened diaphragm spring, or worn spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transmission input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
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 retainerLubricate 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 fly-
wheel.
Weakened engine mounting or loosened engine
mounting bolt or nutRetighten or replace mount-
ing.
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.

7C-4 CLUTCH
ON-VEHICLE SERVICE
CLUTCH CABLE
REMOVAL
1) Disconnect negative cable at battery.
2) Remove clutch cable joint nut (1).
3) Remove joint pin (2) from clutch release lever (3).
4) Disconnect cable hook (1) from clutch pedal (4).
5) Remove clutch cable (3) from bracket (5) by turning cable
cap (2) about 90° as shown.
1. Clutch cable 6. Pedal bracket
2. Release lever 7. Adjusting bolt
3. Joint pin
: Apply grease 99000-25010 to joint pin.8. Lock nut
4. Joint nut 9. Clutch cable hook
: Apply grease 99000-25010 to cable hook.
5. Clutch pedal Tightening torque

CLUTCH 7C-5
INSPECTION
Inspect clutch cable and replace it for any of the following condi-
tions.
Excessive cable friction
Frayed cable
Bent or kinked cable
Broken boots
Worn end
INSTALLATION
1) Apply grease to cable end hook and also joint pin before
installing cable.
“A” : Grease 99000-25010
2) Hook cable end with pedal by using screwdriver or long nose
pliers from cabin inside, then join inner cable wire joint pin in
release lever.
3) Install clutch cable (2) to bracket (3) by turning cable cap (1)
about 90° as shown.
4) Screw in joint nut and adjust free travel of pedal to specifica-
tion by turning nut.
5) Check clutch for proper function with engine running.
NOTE:
Take care that cable grommet (4) has specific installing
direction as shown in the figure.

7C-6 CLUTCH
CLUTCH PEDAL AND CLUTCH PEDAL BRACKET
1. Clutch cable hook
: Apply grease 99000-25010 to cable
hook.7. Pedal spring
: Apply grease 99000-25010 to inside surface
of spring.13. Adjusting bolt cap
2. Clutch pedal bracket 8. Pedal shaft spacer
: Apply grease 99000-25010 to outside sur-
face of spacer.14. Adjusting bolt
3. Bolt 9. Pedal shaft 15. Lock nut
4.
Nut10.
Clutch pedalTightening torque
5. Pedal shaft nut 11. Pedal pad
6. Pedal bush 12. Pedal return cushion

CLUTCH 7C-7
CLUTCH PEDAL HEIGHT
Adjust clutch pedal (1) height with adjusting bolt (2) located on
pedal bracket (3) so that clutch pedal height is same as brake
pedal (4) height.
Height difference
“a” : 0 mm (0 in.)
CLUTCH PEDAL FREE TRAVEL
1) Confirm that clutch pedal height is specification.
2) Depress clutch pedal (1), stop the moment clutch resistance
is felt, and measure distance (clutch pedal free travel). Free
travel should be within the following specification.
Pedal free travel
“b” : 15 – 20 mm (0.6 – 0.8 in.)
3) If free travel is out of specification, adjust it with cable joint
nut (1).
Release lever free travel (Reference)
“c” : 0 – 2 mm (0 – 0.08 in.)
4) After checking clutch pedal free travel, also check clutch for
proper function with engine running.