2000 SUZUKI SWIFT torque

7A-14 MANUAL TRANSMISSION
GEAR SHIFTER & DIFFERENTIAL
38. Countershaft 4th gear 42. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.46. 2nd gear synchronizer inner ring
39. Countershaft left bearing 43. Reverse shaft bolt
: Apply thread lock cement 99000-32110 to thread part of bolt.Tightening torque
40. Bearing set shim 44. Washer Do not reuse.
41. Countershaft 5th gear 45. Center cone Apply transmission oil.

MANUAL TRANSMISSION 7A-15
[A] : GEAR SHIFTER 12. Reverse gear shift arm 25. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around
thread part of bolt.
[B] : DIFFERENTIAL 13. 5th gear shift fork 26. 5th gear shift fork plug
: Apply thread lock 99000-32110 to all around
thread part of plug.
1. Gear shift & select shaft 14. Side gear washer 27. Guide case
2. 5th & reverse gear shift cam 15. Differential side pinion gear 28. Select lever shaft bush
: Apply grease 99000-25010 to whole area of
bush.
3. Gear shift interlock plate 16. Differential side gear 29. Select lever boss
: Apply grease 99000-25010 to internal and exter-
nal diameter
4. Gear shift & select lever 17. Side gear washer 30. Final gear bolt
: Apply thread lock 99000-32110 to all around
thread part of bolt
5. Shift cable lever 18. Differential side oil seal
: Apply grease 99000- 25010 to oil
seal lip.31. Differential pinion shaft
6. Select cable lever 19. Differential side bearing 32. Differential pinion shaft pin
7. Low speed gear shift shaft 20. Speed sensor ring Tightening torque
8. High speed gear shift shaft 21. Differential case Do not reuse.
9. 5th & reverse gear shift shaft 22. Final gear Apply transmission oil.
10. Reverse gear shift lever 23. 5th to reverse interlock guide bolt
: Apply sealant 99000-31110 to bolt
thread.
11. 5th & reverse gear shift guide
shaft24. Gear shift interlock bolt
: Apply sealant 99000-31110 to bolt
thread.

MANUAL TRANSMISSION 7A-17
18) Remove engine left mounting (1) with bracket (2).
19) Remove other attached parts from transmission, if any.
20) Pull transmission out so as to disconnect input shaft from
clutch disc and then lower it.
REMOUNTING
Remount transmission in reverse order of dismounting procedure
noting the following.
 Refer to Section 7D for installing transfer (if equipped).
 Refer to the first figure of “UNIT REPAIR OVERHAUL” for
fastener specified torque.
 Push in drive shaft joints (right & left) fully so as to snap ring
of shaft engages with differential gear.
 Set each clamp for wiring securely.
 After connecting clutch cable, be sure to adjust its play prop-
erly.
Refer to Section 7C.
 Fill transmission with oil as specified.
 Connect battery and check function of engine, clutch and
transmission.
UNIT DISASSEMBLY
FIFTH GEARS
1) Remove side cover bolts and take off transmission side
cover.
CAUTION:
Care should be taken not to scratch oil seal lip with drive
shaft while raising transmission.
Do not hit drive shaft joint with hammer when installing it
into differential gear.
CAUTION:
Care should be taken not to distort side cover when it is
removed from left case.

MANUAL TRANSMISSION 7A-21
SUB ASSEMBLY SERVICE
RIGHT CASE
1) Install input shaft oil seal (1) facing its spring side upward.
Use special tool and hammer for installation and apply
grease to oil seal lip.
“B” : Grease 99000-25010
Special tool
(A) : 09951-76010
2) Install countershaft right bearing cup (2) by using special
tools and hammer.
Special tool
(B) : 09924-74510
(C) : 09925-68210
LEFT CASE
1) If input oil gutter has been removed, install it with bolt to
which thread lock cement have been applied.
“A” : Thread lock cement 99000-32110
Tightening torque
Oil gutter bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
2) Install differential side left oil seal (1) facing its spring side
inward until it becomes flush with case surface by using spe-
cial tool with hammer, and then apply grease to its lip.
“B” : Grease 99000-25010
Special tool
(A) : 09913-75510
3) Install counter shaft left bearing cup into case bore by tap-
ping it with plastic hammer lightly. NOTE:
Before installation, wash each part and apply specified
gear oil to sliding faces of bearing and gear.

7A-32 MANUAL TRANSMISSION
3) Drive in new differential pinion shaft pin (2) till the depth from
differential case (3) surface is about 1 mm (0.04 in.).
4) Press-fit new sensor rotor (1) with groove (4) side downward
as shown by using special tools and copper hammer.
Special tool
(A) : 09913-75510
(B) : 09940-54910
5) Press-fit left bearing by using special tools and copper ham-
mer.
6) Support differential assembly (1) as illustrated so as to left
bearing (2) is floating, and then press-fit right bearing (3) like
left bearing in Step 5).
Special tool
(C) : 09951-76010
(D) : 09951-16060
7) Hold differential assembly with soft jawed vise (3), install final
gear (2) as shown in figure and then tighten bolts (1) with
thread lock cement applied to specified torque.
“A” : Thread lock cement 99000-32110
Tightening torque
Final gear bolts (a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
NOTE:
Make sure to install final gear in correct installing direc-
tion.
CAUTION:
Use of any other bolts than specified ones is prohibited.
4. Groove

MANUAL TRANSMISSION 7A-33
UNIT ASSEMBLY
DIFFERENTIAL TO LEFT CASE
ASSEMBLY
1) Install differential assembly (1) into right case (2).
2) Insert VSS (3) with grease applied to its O-ring, then tighten
it with bolt.
Grease 99000-25010
3) Join input shaft (5), countershaft (4), low speed gear shift
shaft (2) and high speed gear shift shaft (3) assemblies all
together, then install them into right case (1).
4) Install 5th & reverse gear shift shaft (1) with 5th & reverse
gear shift guide shaft (2) into right case (5). Reverse gear
shift arm (4) has to be joined with reverse gear shift lever (3)
at the same time.
5) Place reverse gear shift lever, fasten it with bolts after apply-
ing thread lock cement.
“A” : Thread lock cement 99000-32110
Tightening torque
Revers gear shift lever bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Distance between lever end and shaft bore
“a” : 5 mm (0.2 in.)
CAUTION:
Take care not to damage oil seal lip by input shaft, or oil
leakage may take place.
NOTE:
 Input shaft right bearing on shaft can be installed into
right case by tapping shaft with plastic hammer.
 Check to make sure that counter shaft is engaged with
final gear while installing.
NOTE:
 When installing reverse gear shift lever, set it as the
following specification.

7A-34 MANUAL TRANSMISSION
6) Make reverse idler gear (1) with reverse gear shift lever (2),
insert reverse gear shaft (3) into case through idler gear and
then align “A” in shaft with “B” in case.
7) Clean mating surfaces of both right and left cases, apply
sealant to right case (2) by using a nozzle as shown in figure
by such amount that its section is 1.5mm (0.059 in.) in diam-
eter then mate it with left case (1).
“B” : Sealant 99000-31110
8) Tighten case bolts (3) from left case side to specified torque.
Tightening torque
Transmission case bolts (b) : 19 N·m (1.9 kg-m, 14.0 Ib-ft)
9) Install reverse shaft bolt (4) to which thread lock cement
have been applied with aluminum washer and tighten it.
“A” : Thread lock cement 99000-32110
Tightening torque
Reverse shaft bolt (c) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
10) Install another case bolts from clutch housing side and
tighten them to specification. NOTE:
 Distance “a” can be measured by installing reverse
gear shaft provisionally.
 When “a” is 5 mm (0.2 in.), clearance between reverse
idler gear groove and shift lever end will be 1 mm (0.04
in.).
NOTE:
 Make sure that washer (4) has been installed in shaft at
above the gear.
 Check to confirm that reverse gear shift lever end has
clearance 1 mm (0.04 in.) to idler gear groove.

MANUAL TRANSMISSION 7A-35
11) Check locating spring for deterioration and replace with new
one as necessary.
Locating spring free length
For Low speed (3) and 5th & reverse (6)
Standard : 26.1 mm (1.028 in.)
Service Limit : 25.0 mm (0.984 in.)
For High speed (5)
Standard : 40.1 mm (1.579 in.)
Service Limit : 39.0 mm (1.535 in.)
12) Install steel ball (4) and locating spring for respective gear
shift shaft and tighten bolt (1) to which sealant have been
applied to its thread part.
Sealant 99000-31110
Tightening torque
Locating spring bolts (d) : 13 N·m (1.3 kg-m, 9.5 Ib-ft)
FIFTH GEARS
1) To seat countershaft left bearing cup (1) to bearing cone, tap
cup by using special tool and plastic hammer.
Special tool
(A) : 09913-84510
2) Put a shim (2) on bearing cup (3) provisionally, place straight
edge (1) over it and compress it by hand through straight
edge, and then measure “a” (Clearance between case sur-
face (4) and straight edge) by using feeler gauge (5).
Clearance between case surface and straight edge
“a” : 0.13 – 0.17 mm (0.0051 – 0.0067 in.)
(Shim protrusion)
3) By repeating above step, select a suitable shim which
adjusts clearance “a” to specification and put it on bearing
cup.
2. Washer
NOTE:
Insert 0.15 mm (0.0059 in.) feeler to know whether or not
a shim fulfills specification quickly.