2000 SUZUKI SWIFT Clutch

7B-102 AUTOMATIC TRANSMISSION (4 A/T)
Direct Clutch Piston Lip and Direct Clutch Balancer Lip
Check each lip for wear, deformation, cut, and/or hardening. If
necessary, replace.
ASSEMBLY
1) Install new D-ring (5) to direct clutch No.1 drum (6).
Apply grease to D-ring and fit it to drum.
“A”: Grease 99000-25030
2) Install piston (4) into direct clutch No.1 drum.
Use care that the piston lip does not get twisted or caught.
Apply grease to the lip of the piston.
“A”: Grease 99000-25030
3) Install direct clutch return spring seat (3) and direct clutch
balancer (2).
4) Install new shaft snap ring (1).
Compress return springs and install shaft snap ring in groove
by using a flat end rod or the like (3).
Place special tool (clutch spring compressor) on spring seat
and compress springs with a press (2).
Special tool
(A) : 09926-96010
5) Install discs, plates and flange (1) in following order.
(1) Flange No.1 →
(2) Disc →
(3) Plate →
(4) Disc →
(5)
Flange No.2
1. Snap ring
CAUTION:
Do not compress return spring more than necessary.
NOTE:
Before assembly, new discs should be soaked in auto-
matic transmission fluid for at least 2 hours.

AUTOMATIC TRANSMISSION (4 A/T) 7B-103
6) Install snap ring (1).
7) Place special tool (A) on soft jawed vise (1) and install 2 oil
seal rings on special tool.
Special tool
(A) : 09926-26050
(B) : Rear cover seal ring 24742-78F10 SUZUKI GENUINE
PARTS
8) Place direct clutch assembly (1) on special tool (A).
9) Set dial gauge (4) on the top of clutch flange (2) and mea-
sure clearance by blowing compressed air (4 kg/cm
2, 57 psi)
as shown in figure.
If the clearance is out of specification, replace clutch discs,
plates and flange.
Direct clutch disc clearance
: 0.50 – 1.04 mm (0.0197 – 0.0409 in.) NOTE:
Make sure that the ends of the snap ring do not come to
the opening of the front clutch No.1 drum.
NOTE:
 Rear cover seal set has two seal rings in a set.
 Do not use the seal rings removed from rear cover. It is
not necessary to remove seal rings from special tool
once installed.
3. Air gun

7B-104 AUTOMATIC TRANSMISSION (4 A/T)
10) Attach special tool (B) to dial gauge (2) and set them on the
lowest clutch plate.
Special tool
(B) : 09952-06010
11) Measure piston stroke by blowing compressed air (4 kg/cm
2,
57 psi) as shown in figure.
Direct clutch piston stroke
: 0.96 – 1.14 mm (0.0378 – 0.0449 in.)
PLANETARY SET
1. Direct clutch assembly
3. Air gun
1. Planetary ring gear No.2 4. Thrust needle roller bearing 7. Snap ring
2. Planetary gear assembly No.2 5. Planetary gear assembly No.1 Apply automatic transmission fluid.
3. Planetary oil receiver No.2 6. Planetary oil receiver No.1 Do not reuse.

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-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.

AUTOMATIC TRANSMISSION (4 A/T) 7B-129
44) Apply grease to thrust needle roller bearing (1) and install it.
“A” : Grease 99000-25030
45) Apply grease to clutch drum thrust washer (1) and install it to
oil pump assembly (2).
“A” : Grease 99000-25030
46) Install new gasket to transmission case and install oil pump
assembly (1) to transmission case.
Tightening torque
Oil pump assembly bolts (a) : 12 N·m (1.2 kg-m, 9.0 lb-ft)
47) Measure input shaft end (2) play.
Set dial gauge (1) as shown in figure and measure the play
of the input shaft.
Input shaft end Play
Standard : 0.3 – 0.7 mm (0.012 – 0.028 in.)
48) If the obtained value is out of standard value, select thrust
bearing race (installed in step 41)) of different thickness
shown in table below and adjust the play.
Available thrust bearing race size (thickness)
1.3 mm (0.051 in.), 1.7 mm (0.067 in.) or 2.1 mm (0.083 in.)
3. Oil pump