2000 SUZUKI SWIFT torque

7A-36 MANUAL TRANSMISSION
Available shim thickness
0.40, 0.45, 0.50, 0.55, 0.6, 0.65,0.7, 0.75, 0.8, 0.85, 0.9, 0.95,
1.0,1.05, 1.1 and 1.15 mm (0.015, 0.017, 0.019, 0.021,
0.023,0.025, 0.027, 0.029, 0.031, 0.033,0.035, 0.037, 0.039,
0.041, 0.043 and 0.045 in.)
4) Place left case plate (2) inserting its end in groove of shift
guide shaft (4) and tighten new adhesive pre-coated
screw(s) (1) (and new adhesive per-coated bolts (7) tempo-
rarily with less than specified toque.
5) Tighten new screw(s) (and new bolts) to specified torque
finally in the order of circled numbers (➀→➁→➂→➃→➄→➅
) shown in figure.
Tightening torque
Left case plate screw(s) (and bolts)
(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
6) Assemble 5th speed synchronizer sleeve (4) and hub (3)
with keys (2) and springs (1).
Synchronizer key installation position
: A = B
7) Install 5th gear (1) to counter shaft facing machined boss A
inward. CAUTION:
Do not reuse left case plate screw(s) (1) (and bolts (7)).
Be sure to use new adhesive pre-coated screw(s) (and
new adhesive pre-coated bolts). Otherwise, screw(s)
(and/or bolts) may loosen.
NOTE:
After tightening screw(s) (and bolts), make sure that
countershaft (5) can be rotated by hand feeling certain
load.
[A]: In case 6 screws are used 3. Input shaft
[B]: In case 1 screw and 5 bolts are used 6. Transaxle left case
NOTE:
Short side C in keys, long flange D in hub and chamfered
spline F in sleeve should face inward (5th gear side).
[A] : Short side C D : Long flange (Inward)
[B] : Long side E : Key way
C : Short side (Inward) F : Chamfered spline (Inward)
A : Machined boss (Inside)
B : No machining (Outside)

MANUAL TRANSMISSION 7A-37
8) Install needle bearing of separated steel cage type to input
shaft, apply oil then install 5th gear (1) and special tool to
stop shaft rotation.
Special tool
(B) : 09927-76010
9) Install new countershaft nut (2) and tighten it to specification.
Tightening torque
Countershaft nut (b) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
10) Remove special tool, then caulk nut at C with caulking tool
and hammer.
11) Install synchronizer ring (2).
12) Fit 5th gear shift fork (1) to sleeve & hub assembly (3) and
install them into input shaft, shift shaft and shift guide shaft at
once aligning hub oil groove A with shaft mark B.
13) Drive in spring pin facing its slit A outward.
14) If equipped, install steel ball, tighten shift fork plug (3) to
which thread lock cement have been applied.
“A” : Thread lock 1322 99000-32110
Tightening torque
5th shift fork plug (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
15) Fit hub plate (1) and fix it with circlip (2).
16) If equipped, install circlip (4) to the end of 5th & reverse gear
shift guide shaft.
NOTE:
Long flange of hub faces inward (gear side).
A : Oil groove (Align with B)
B : Punch mark
C : Caulking
CAUTION:
 Coat shift fork plug with thread lock cement reason-
ably. If it is done to much, excess may interfere in ball
movement and cause hard shift to 5th speed.
 Make sure circlip is installed in shaft groove securely.
A : Pin slit (Face outward)

7A-38 MANUAL TRANSMISSION
17) Clean mating surface of both left case (2) and side cover (1),
apply sealant to side cover (1) by using a nozzle as shown in
figure by such amount that its section is 1.5mm (0.059 in.) in
diameter, mate it with left case and then tighten bolts.
“B” : Sealant 99000-31110
Tightening torque
Side cover No.1 bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Side cover No.2 bolts (b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
GEAR SHIFT AND SELECT SHAFT ASSEMBLY
1) Clean mating surface of guide case.
2) Apply grease to select lever shaft bush and select lever
boss, and install gear shift and select shaft assembly with
new gasket into transmission.
“A” : Grease 99000-25010
3) Apply sealant to gear shift guide case No. 2 bolt (5). Tighten
gear shift guide case No. 1 bolts (1) and No. 2 bolt (5) to
specified torque at the position that clearance “a” is within 1 -
1.5 mm (0.04 - 0.06 in.).
Tightening torque
Guide case bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
4) Install washer and gear shift interlock bolt (2) to which seal-
ant have been applied and them tighten it to specified
torque.
“B” : Sealant 99000-31110
Tightening torque
Gear shift inter lock bolt (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
5) Install washer and 5th to reverse interlock guide bolt (3) to
which sealant have been applied and then tighten it to speci-
fied torque.
“B” : Sealant 99000-31110
Tightening torque
5th to reverse interlock guide bolt (a) : 23 N·m (2.3 kg-m,
17.0 lb-ft)

MANUAL TRANSMISSION 7A-39
6) Tighten backup lamp switch (1) to specified torque.
Tightening torque
Backup lamp switch (b) : 19 N·m (1.9 kg-m, 14.0 lb-ft)
7) Check input shaft for rotation in each gear position.
8) Also confirm function of back up light switch in reverse posi-
tion by using ohmmeter.
TIGHTENING TORQUE SPECIFICATION
Fastening partTightening torque
Nm kg-m lb-ft
Transmission oil level/filler and drain plugs 21 2.1 15.5
Oil gutter bolt 10 1.0 7.5
Final gear bolts 90 9.0 65.0
Reverse gear shift lever bolts 23 2.3 17.0
Transmission case bolts 19 1.9 14.0
Reverse shaft bolt 23 2.3 17.0
Locating spring bolts 13 1.3 9.5
Left case plate screw 9 0.9 6.5
Countershaft nut 60 6.0 43.5
5th shift fork plug 10 1.0 7.5
Side cover No.1 bolts 10 1.0 7.5
Side cover No.2 bolts 23 2.3 17.0
Guide case bolts 23 2.3 17.0
Gear shift interlock bolt 23 2.3 17.0
5th to reverse interlock guide bolt 23 2.3 17.0
Backup lamp switch 19 1.9 14.0

7B-2 AUTOMATIC TRANSMISSION (4 A/T)
DTC P0702/P1702 (DTC No.52)
TRANSMISSION CONTROL SYSTEM
ELECTRICAL OR INTERNAL
MALFUNCTION OF TCM ....................... 7B-52
INSPECTION OF TCM AND ITS
CIRCUITS ............................................... 7B-53
ON-VEHICLE SERVICE ................................. 7B-55
MAINTENANCE SERVICE ......................... 7B-55
FLUID LEVEL AT NORMAL OPERATING
TEMPERATURE ..................................... 7B-55
FLUID LEVEL AT ROOM
TEMPERATURE ..................................... 7B-56
FLUID CHANGE ..................................... 7B-56
SELECTOR LEVER .................................... 7B-57
TRANSMISSION RANGE SENSOR
(SHIFT SWITCH) ........................................ 7B-58
SELECTOR CABLE .................................... 7B-60
OUTPUT SHAFT SPEED SENSOR
(A/T VSS) .................................................... 7B-62
INPUT SHAFT SPEED SENSOR ............... 7B-63
VEHICLE SPEED SENSOR (VSS)............. 7B-63
THROTTLE POSITION SENSOR............... 7B-63
ENGINE COOLANT TEMP. (ECT)
SENSOR ..................................................... 7B-64
DROPPING RESISTOR ............................. 7B-64
O/D OFF SWITCH ...................................... 7B-65
SHIFT SOLENOID VALVES AND
TRANSMISSION TEMPERATURE
SENSOR ..................................................... 7B-65
SHIFT SOLENOID VALVES ................... 7B-66
TRANSMISSION TEMPERATURE
SENSOR ................................................. 7B-66
DIFFERENTIAL SIDE OIL SEAL ................ 7B-68TRANSMISSION CONTROL MODULE
(TCM).......................................................... 7B-69
LEARNING CONTROL INITIALIZATION 7B-70
BRAKE INTERLOCK SYSTEM
(IF EQUIPPED)........................................... 7B-70
KEY INTERLOCK CABLE
(IF EQUIPPED)........................................... 7B-72
TRANSMISSION UNIT REPAIR
OVERHAUL ................................................... 7B-75
DISMOUNTING .......................................... 7B-76
REMOUNTING ........................................... 7B-77
UNIT DISASSEMBLY ................................. 7B-78
DISASSEMBLY/ASSEMBLY OF
SUBASSEMBLY ......................................... 7B-88
OIL PUMP ............................................... 7B-88
FRONT CLUTCH (C2 CLUTCH) ............ 7B-91
REAR CLUTCH (C1 CLUTCH) ............... 7B-95
DIRECT CLUTCH (C0 CLUTCH) ......... 7B-100
PLANETARY SET................................. 7B-104
VALVE BODY ....................................... 7B-106
DIFFERENTIAL ASSEMBLY ................ 7B-112
REAR COVER (O/D BRAKE PISTON
ASSEMBLY) ......................................... 7B-115
PLANETARY SUN GEAR NO.1
ASSEMBLY .......................................... 7B-115
TORQUE CONVERTER HOUSING ..... 7B-116
TRANSMISSION CASE ........................ 7B-117
UNIT ASSEMBLY ..................................... 7B-118
TIGHTENING TORQUE SPECIFICATION .. 7B-136
SPECIAL TOOL ........................................... 7B-137
REQUIRED SERVICE MATERIAL .............. 7B-139

AUTOMATIC TRANSMISSION (4 A/T) 7B-3
GENERAL DESCRIPTION
This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D).
The torque converter is a 3-element, 1-step and 2-phase type equipped with lock-up mechanism. The gear shift
device consists of 2 sets of planetary gear units, sets of 3 disc type clutches, 3sets of disc type brakes and one-
way clutch. The gear shift is done by selecting one of 6 positions (“P”, “R”, “N”, “D”, “2” and “L”) by means of the
select lever installed on the floor. On the shift knob, there is an overdrive (O/D) cut switch which allows shift-up
to the overdrive mode and shift-down from the overdrive mode.
1. Final gear 6. Overdrive brake (B0) 11. Oil strainer 16. Front clutch (C2)
2. Differential gear assembly 7. Direct clutch (C0) 12. Counter drive gear (Reduction gear) 17. Reverse brake (B2)
3. Parking gear 8. Rear planetary gear 13. Oil pump 18. Rear clutch (C1)
4. Counter driven gear (Reduction gear) 9. Front planetary gear 14. Input shaft 19. Differential drive pinion shaft
5. 1st and 2nd brake (B1) 10. Valve body assembly 15. Torque converter

7B-4 AUTOMATIC TRANSMISSION (4 A/T)
Item Specifications
Torque
converterType
Stall torque ratio3-element, 1-step, 2-phase type
1.65 –1.85
Oil pumpType
Drive systemInternal gear type oil pump
Engine driven
Gear
change
deviceType Forward 4-step, reverse 1-step planetary gear type
Shift position“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range
(O/D ON)Forward 1st ↔
2nd ↔
3rd ↔
4th (O/D)
automatic gear change
“D” range
(O/D OFF)Forward 1st ↔
2nd ↔
3rd ←
4th
automatic gear change
“2” range Forward 1st ↔
2nd ←
3rd automatic gear change
“L” range Forward 1st ←
2nd reduction, and fixed at 1st gear
Gear
ratio1st 2.962
2nd 1.515 Number of teeth Front sun gear : 34
Rear sun gear : 21
Front pinion gear : 16
Rear pinion gear : 19
Front internal gear : 66
Rear internal gear : 59 3rd 1.000
4th
(overdrive gear)0.737
Reverse
(reverse gear2.809
Control elementsWet type multi-disc clutch ... 3 sets
One-way clutch ... 1 set
Wet type multi-disc brake ... 3 sets
Reduction gear ratio 1.209
Final gear ratio
(Differential)3.578 (for 2WD vehicle), 3.894 (for 4WD vehicle)
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Water-cooled
Fluid used
Equivalent of DEXRON
-III or DEXRON-IIE

AUTOMATIC TRANSMISSION (4 A/T) 7B-19
TABLE 2 (MECHANICAL)
Condition Possible Cause Correction
Vehicle does not move
at any rangeManual valve faulty Clean or replace.
Primary regulator valve faulty Clean or replace.
No gear
change
1st
↔
↔↔ ↔ 2nd
Shift solenoid -D (No.4) and/or -E (No.5)
stuck Clean or replace.
2nd
↔
↔↔ ↔ 3rd
Shift solenoid -A (No.1), -C (No.3) and/or fail
valve No.1 stuckClean or replace.
3rd
↔
↔↔ ↔ 4th
Shift solenoid -B (No.2), -C (No.3) and/or fail
valve No.2 stuckClean or replace.
Harsh engagement
P, N
→
→→ → R
Front clutch accumulator faulty Clean or replace.
N
→
→→ → D
1st & 2nd brake accumulator faulty Clean or replace.
1st
→
→→ → 2nd at D
range or 2 rangeFront clutch accumulator faulty Clean or replace.
Shift solenoid -D (No.4) Clean or replace.
2nd
→
→→ → 3rd at D
rangeDirect clutch accumulator faulty Clean or replace.
Shift solenoid -E (No.5) Clean or replace.
3rd
→
→→ → 4th at D
rangeOverdrive brake accumulator faulty Clean or replace.
Shift solenoid -B (No.2) Clean or replace.
All gear change
Primary regulator valve faulty Clean or replace.
Excessive slip
(low line pressure)Primary regulator valve faulty Clean or replace.
Vehicle does not
move at
1st, 2nd, 3rd and
reverse gearRear clutch faulty Repair or replace.
Reverse gear
Reverse brake faulty Repair or replace.
2nd, 3rd and 4th
gearFront clutch faulty Repair or replace.
3rd and 4th gear
Direct clutch faulty Repair or replace.
1st and 2nd gear
1st & 2nd brake faulty Repair or replace.
4th gear
Overdrive brake faulty Repair or replace.
Any forward and
reverse gearParking lock pawl faulty Repair or replace.
Shock or engine stalls
when starting off and
stoppingTCC (lock-up clutch) faulty Inspect and replace as necessary.
TCC (lock-up) solenoid faulty Clean or replace.
Lock-up control valve faulty Clean or replace.
Lock-up signal valve faulty Clean or replace.
No up-shift
1st
→
→→ → 2nd
Front clutch faulty Repair or replace.
2nd
→
→→ → 3rd
Direct clutch faulty Repair or replace.
3rd
→
→→ → 4th
Overdrive brake faulty Repair or replace.
No engine
braking
2nd or 3rd gear
Front, rear or direct clutch or 1st & 2nd brake
faultyRepair or replace
L range 1st gear
Direct clutch or 1st & 2nd brake faulty Repair or replace.
No lock-up
Torque converter clutch faulty Inspect and replace as necessary.
Lock-up control valve faulty Clean or replace.
TCC (lock-up) solenoid faulty Clean or replace.
Secondary regulator valve faulty Clean or replace.
Signal valve faulty Clean or replace.