2000 SUZUKI SWIFT transmission oil

7A-16 MANUAL TRANSMISSION
TRANSMISSION UNIT
DISMOUNTING
Under Hood
1) Disconnect negative cable at battery.
2) Undo wiring harness clamps, disconnect backup lamp switch
coupler, VSS coupler and ground cable.
3) Disconnect clutch cable from clutch release lever and
bracket.
4) Disconnect gear shift and select control cables.
5) Remove water pipe bracket bolts from transmission.
6) Remove transmission bolts (1).
7) Remove starting motor taking out its bolts.
8) Support engine by using lifting device.
On Lift
9) Drain transmission oil referring to “OIL CHANGE” in this sec-
tion.
10) Remove left and right drive shaft referring to Section 4A.
11) Remove left side of engine under cover.
12) Remove engine rear mounting bracket stiffener (1).
13) Remove clutch housing lower plate.
14) Remove engine rear mounting No.1 bracket (2) with No.2
bracket (3).
15) Remove transfer referring to Section 7D (if equipped).
16) Remove transmission to engine bolt and nut.
17) Lower vehicle and support transmission with transmission
jack.

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.

7A-20 MANUAL TRANSMISSION
11) Tapping input shaft end with plastic hammer, push it out as
assembly from case a little, then take out input shaft assem-
bly (1), counter shaft assembly (2), high speed gear shift
shaft (3) and low speed gear shift shaft (4) all at once.
12) Remove counter shaft left bearing cup from left case.
13) Remove differential side left oil seal also from left case.
RIGHT CASE
1) Remove differential gear assembly (1) from right case (2).
2) Remove bolt and then pull out VSS (3).
3) If input shaft right bearing has been left in right case, pull it
out by using special tools.
Remove input shaft oil seal (1) by using special tools.
Special tool
(A) : 09930-30104
(B) : 09923-74510
4) Also pull out countershaft right bearing cup (2) by using spe-
cial tools.
Special tool
09941-64511
09923-30104

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.

MANUAL TRANSMISSION 7A-23
INSPECTION AND REASSEMBLY
1) Clean all components thoroughly, inspect them for any
abnormality and replace with new ones as necessary.
2) If synchronizer parts need to be repaired, check clearance
“a” between ring (2) and gear (1), each chamfered tooth of
gear, ring and sleeve, then determine parts replacement.
Clearance between synchronizer ring and gear
Standard “a” : 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit “a” : 0.5 mm (0.019 in.)
3) To ensure lubrication, air blow oil holes (1) and make sure
that they are free from any obstruction.
4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3
keys (2) in it and then set springs (1) as shown in figure.
Synchronizer key installation position
: A = B
5) Drive in right bearing (1) to input shaft (2) by using special
tool and hammer.
Special tool
(A) : 09913-80112
NOTE:
 No specific direction is assigned to each key but it is
assigned as sleeve & hub assembly.
 Size of high speed synchronizer sleeve, hub, keys and
springs is between those of low speed and 5th speed
ones.
[A] : 3rd gear side
C : Long flange
D : Key way
E : Projecting end

7A-24 MANUAL TRANSMISSION
6) Install 3rd gear needle bearing of resin cage type, apply oil to
it, then install 3rd gear (1) and synchronizer ring (2).
7) Drive in high speed sleeve & hub assembly (3) by using spe-
cial tool and hammer, facing long flange side of hub to 3rd
gear.
Special tool
(B) : 09913-84510
8) Install circlip (1) and confirm that circlip is installed in groove
securely.
Install needle bearing (2) of steel cage type, apply oil to
bearing and then install synchronizer ring (3) and 4th gear
(4).
9) Press-fit left bearing (2) by using special tool and hammer.
Special tool
(C) : 09925-98221
10) Using the same special tool, drive in 5th gear spacer (1).NOTE:
 While press-fitting sleeve & hub, make sure that syn-
chronizer ring key slots are aligned with keys in sleeve
& hub assembly.
 Check free rotation of 3rd gear after press-fitting
sleeve & hub assembly.
 Synchronizer rings for 3rd and 4th are identical.
[A] : 3rd gear side
A : Key way
B : Long flange
C : Projecting end
CAUTION:
To prevent 5th gear spacer from being distorted because
of excessive compression, do not press-fit it with left
bearing at once.

7A-26 MANUAL TRANSMISSION
8) Remove right bearing cone (2) by using puller (3), metal stick
(1) and press.
INSPECTION AND REASSEMBLY
1) Clean all components thoroughly, inspect them for any
abnormality and replace with new ones as necessary.
2) If synchronizer parts need to be repaired, check clearance
“a” between ring (2) and gear (1), each chamfered tooth of
gear, ring and sleeve, then determine parts replacement.
Clearance between synchronizer ring and gear
Standard “a” : 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit “a” : 0.5 mm (0.019 in.)
3) Put the synchronizer outer ring (1), inner ring (3) and the
cone (2) together and then measure the step difference
between the outer ring and the inner ring. And also check
each chamfered tooth of gear and synchronizer ring and
replace with new one, if necessary. Also, check gear tooth.
Difference between synchronizer outer ring and inner ring
Standard “b” : 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit “b” : 0.5 mm (0.019 in.)
4) To ensure lubrication, air blow oil holes (1) and make sure
that they are free from any obstruction.

MANUAL TRANSMISSION 7A-27
5) Fit low speed synchronizer sleeve (4) to hub (3), insert 3
keys (2) in it and then set springs (1) as shown in figure.
Synchronizer key installation position
: A = B
6) Install right bearing cone (1) to counter shaft (2) by using
special tool and hammer.
Special tool
(A) : 09923-78210
7) Install needle bearing of resin cage type, apply oil to it, then
install 1st gear and 1st gear synchronizer ring.
8) Drive in low speed sleeve & hub assembly (1) by using spe-
cial tools and hammer, facing “B” side of sleeve to 1st gear.
Special tool
(A) : 09923-78210
(B) : 09925-18011
(C) : 09940-53111 NOTE:
 No specific direction is assigned to each key but it is
assigned as sleeve & hub assembly.
 Size of low speed synchronizer keys and springs are
the largest compared with those of high speed and 5th
speed ones.
[A] : 1st gear side
C : Key way
D : Short flange
NOTE:
 Support shaft with special tool as shown in figure so
that retainer of bearing cone (4) will be free from com-
pression.
 Make sure that synchronizer ring (2) key slots are
aligned with keys while press-fitting sleeve & hub
assembly.
 Check free rotation of 1st gear (3) after press-fitting
sleeve & hub assembly.
A : Align key slots with keys