2000 SUZUKI SWIFT rear brake

AUTOMATIC TRANSMISSION (4 A/T) 7B-23
ENGINE BRAKE TEST
1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake
operates.
2) In the same way as in Step 1), check engine brake for operation when select lever is shifted down to “L”
range.
3) Engine brake should operate in above test.
“P” RANGE TEST
1) Stop vehicle on a slope, shift select lever to “P” range and at the same time apply parking brake.
2) After stopping engine, depress brake pedal and release parking brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to “N” range.
5) Then, release brake pedal gradually and check that vehicle moves.WARNING:
Before test, make sure that there is no vehicle behind so as to pre-
vent rear-end collision.
Test result Possible cause
Fails to operate when shifted down to “2”
rangeDefective shift switch
1st & 2nd brake defective
Direct clutch defective
Fails to operate when shifted down to “L”
range
WARNING:
Before test, check to make sure no one is around vehicle or
down on a slope and keep watchful for safety during test.
Test result Possible cause
Vehicle moves at “P” range or
remains stationary at “N” rangeDefective parking lock pawl or
spring

AUTOMATIC TRANSMISSION (4 A/T) 7B-75
TRANSMISSION UNIT REPAIR OVERHAUL
NOTE:
When transmission is replaced, or when clutch or brake disc, plate and/or flange is changed to new
and/or used one, all learned contents which are stored in TCM memory should be erased referring to
“LEARNING CONTROL INITIALIZATION” in this section.
1. Torque converter 9. Counter drive gear 17. 1st & 2nd brake (B1) assembly
2. Torque converter housing 10. Reverse brake (B2) piston assembly 18. Planetary gear assembly
3. Oil pump assembly 11. A/T oil pan 19. O/D brake (B0) assembly
4. Front clutch (C2) assembly 12. Oil strainer 20. Planetary sun gear No.1 assembly
5. Rear Clutch (C1) assembly 13. Valve body assembly 21. Direct clutch (C0) assembly
6. Reverse brake (B2) assembly 14. Transmission case 22. O/D brake (B0) piston and rear cover assembly
7. Intermediate shaft 15. Counter driven gear assembly
8. Follow shaft 16. 1st & 2nd brake (B1) piston assembly

7B-82 AUTOMATIC TRANSMISSION (4 A/T)
22) Remove rear clutch assembly (1).
23) Remove intermediate shaft assembly (1) and follow shaft
assembly (2).
24) Remove reverse brake (B2) snap ring, brake flange, brake
discs, brake plates and cushion plate.
25) Remove oil guide plate (1) parking lock pawl cover (2), shaft,
torsional spring (3) and parking lock pawl (4).
26) Remove parking lock pawl sleeve (5).

7B-84 AUTOMATIC TRANSMISSION (4 A/T)
31) Remove rear cover assembly (1), thrust washer (2) and
thrust needle roller bearing (3).
Remove gasket (4).
32) Remove direct clutch (C0) assembly (1), thrust roller bearing
(2) and rear planetary sun gear No.1 assembly (3).
33) Remove planetary set (1) with bearing, thrust needle roller
bearing (2).
34) Remove O/D brake (B0) piston adapter (1), B0 plates (2)
and discs (3).

AUTOMATIC TRANSMISSION (4 A/T) 7B-115
REAR COVER (O/D BRAKE PISTON ASSEMBLY)
DISASSEMBLY
1) Remove O/D brake piston (1) from rear cover (2).
2) Remove O-ring (3) and seal ring (4).
Replace them, if damaged.
ASSEMBLY
1) Install seal rings to rear cover and O-rings to O/D brake pis-
ton.
2) Apply grease to O-rings and install O/D brake piston to rear
cover.
PLANETARY SUN GEAR NO.1 ASSEMBLY
DISASSEMBLY
1) Remove one-way clutch retainer (1) from planetary sun gear
No.1 assembly.
2) Remove one-way clutch bearings (2), one-way clutch (3),
inner race (4) and washer (5) from planetary sun gear No.1
(6).
ASSEMBLY
Reverse removal procedure noting followings.
When installing retainer, fit 2 hooks of retainer on planetary
sun gear No.1 and tap the other 2 hooks with plastic ham-
mer.
After assembling, make sure that :
There is no clearance between retainer and bearing. NOTE:
If O/D brake piston is hard to take it out, force low-pres-
sure compressed air (1 kg/cm
2, 15 psi, 100 kPa max) into
hole (5) shown in figure and pop out piston into a rag.
NOTE:
Do not reuse retainer.

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.

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-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.