2000 SUZUKI SWIFT brake

AUTOMATIC TRANSMISSION (4 A/T) 7B-87
INSPECTION
Clutch and Brake Discs
Dry and inspect them for pitting, burn flaking, wear, glazing,
cracking, charring and chips or metal particles imbedded in lining.
If discs show any of the above conditions, replacement is
required.
Clutch and Brake Plates and Flanges
Dry plates and check for discoloration. If plate surface is smooth
and even color smear is indicated, the plate should be reused. If
severe heat spot discoloration or surface scuffing is indicated, the
plate must be replaced.
1st & 2nd Brake Piston Return Spring Subassembly
Measure height of 1st & 2nd brake piston return spring.
Height of 1st & 2nd brake piston return spring
20.81 mm (0.819 in.)
Evidence of extreme heat or burning in the area of clutch may
have caused springs to take a heat set and would require their
replacement.NOTE:
 If disc lining is exfoliated or discolored, replace all
discs.
 Before assembling new discs, soak them in A/T fluid
for at least two hours.
NOTE:
 Do not apply excessive force when measuring spring
height.
 Perform measurement at several points.

7B-88 AUTOMATIC TRANSMISSION (4 A/T)
DISASSEMBLY/ASSEMBLY OF SUBASSEMBLY
OIL PUMP
CAUTION:
 Keep component parts in group for each subassembly and avoid mixing them up.
 Clean all parts with cleaning solvent thoroughly and air dry them.
 Use kerosene or automatic transmission fluid as cleaning solvent.
 Do not use wiping cloths or rags to clean or dry parts.
 All oil passages should be blown out and checked to make sure that they are not obstructed.
 Keep face and eyes away from solvent spray while air blowing parts.
 Check mating surface for irregularities and remove them, if any, and clean it again.
 Soak new clutch discs and brake discs in transmission fluid for at least 2 hours before assembly.
 Replace all gaskets and O-rings with new ones.
 Apply automatic transmission fluid to all O-rings.
 When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
 Replace oil seals that are removed and apply grease to their lips.
 Before installing, be sure to apply automatic transmission fluid to sliding, rolling and thrusting sur-
face of all component part. Also after installation, make sure to check each part for proper opera-
tion.
 Always use torque wrench when tightening bolts.
1. Oil seal
: Apply grease 99000-25030 to oil seal lip.7. Clutch drum thrust washer
2. D-ring
: Apply grease 99000-25030 to all over surface. 8. Clutch drum oil seal ring
: Apply grease 99000-25030 to all over surface.
3. Oil pump body Apply automatic transmission fluid.
4. Oil pump drive gear Tightening torque
5. Oil pump driven gear Do not reuse.
6. Stator shaft assembly

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.

7B-118 AUTOMATIC TRANSMISSION (4 A/T)
2) Install new oil seal to transmission case.
Use special tool to press-fit oil seal until oil seal end face is
flush with transmission case end face.
Special tool
(F) : 09913-75510
UNIT ASSEMBLY
CAUTION:
 Automatic transmission consists of highly precise parts. As even a flaw in a small part may cause
oil leakage or decrease in function, check each part carefully before installation.
 Clean all parts with compressed air. Never use wiping cloths or rags.
 Before assembling new clutch discs and brake band, soak them in automatic transmission fluid for
at least 2 hours.
 Be sure to use new gaskets and O-rings.
 Lubricate O-rings with automatic transmission fluid.
 Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly.
 Use yellow petrolatum grease or Suzuki Super Grease C to retain parts in place.
 Be sure to install thrust bearings and races in correct direction and position.
 Make sure that snap ring ends are not aligned with one of cutouts and are installed in groove cor-
rectly.
 Do not use adhesive cements on gaskets and similar parts.
 Be sure to torque each bolt and nut to specification.

AUTOMATIC TRANSMISSION (4 A/T) 7B-119
1) Install new O-rings (inside (5) and outside (6)) to reverse
brake piston (4), and apply grease to them.
“A” : Grease 99000-25030
2) Install reverse brake piston (4), wave spring (3) and reverse
brake piston seat (2) to transmission case.
3) Install new snap ring (1) by compressing wave spring thru
reverse brake piston seat with hydraulic press (8) and spe-
cial tool.
Special tool
(A) : 09926-96040
4) Install counter drive gear (1).
Tightening torque
Counter drive gear installing bolts
(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft) NOTE:
Don’t compress wave spring more than necessary or it
may get damaged.
7. Flat end rod or the like
2. Transmission case

7B-120 AUTOMATIC TRANSMISSION (4 A/T)
5) Install new inner and outer O-rings (4) to 1st & 2nd brake
piston (3) and apply grease to them.
“A” : Grease 99000-25030
6) Install 1st & 2nd brake piston (3) to transmission case, in
such way that the side with spring holes comes to the top.
Make sure that the O-rings are not twisted or caught.
7) Place 1st & 2nd brake piston return spring subassembly (2)
on piston (3). Make sure that each spring fits the holes on
the piston.
8) Push down return spring subassembly and install snap ring
(1).
9) Install 1st & 2nd brake (B1) discs and plates in following
order.
(1) Plate →
(2) Disc →
(3) Plate →
(4) Disc →
(5) Plate →
(6) Disc →
(7) Plate →
(8) Disc
10) Hold above parts with snap ring.
11) Install brake flange (1) and snap ring (2) to transmission
case (3). CAUTION:
Check that the opening of snap ring does not face the
cored-hole (5) of the transmission case.
NOTE:
The flat surface of the flange comes to the top (must face
O/D brake piston).

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.

7B-122 AUTOMATIC TRANSMISSION (4 A/T)
15) Install thrust needle roller bearing (1) and planetary sun gear
No.2 (2). Turn planetary sun gear No.2 (2) right and left to
match the brake discs and the spline of planetary sun gear
No.2.
16) Install thrust needle roller bearing (3) and planetary set (4).
Turn planetary set (4) right and left to match the gears of the
planetary sun gear No.2 (2) and the gears of the planetary
set (4).
17) Install thrust needle roller bearing (5) and planetary sun gear
No.1 assembly (6). Turn planetary sun gear No.1 assembly
(6) right and left to match the gears of planetary set (4) and
the gears of planetary sun gear No.1 assembly (6).
18) Install O/D brake (B0) discs (1) and plates (2).