2004 SUZUKI SWIFT Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-27
3) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as
shown in figure.
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.

Synchronizer key in stallation position
A = B
4) Drive in right bearing (1) to input shaft (2) using special tool and hammer.
Special tool
(A): 09951–16080
5) Install 3rd gear needle bearing, apply oil to it, then install 3rd gear (1) and synchronizer ring (2).
6) Drive in high speed synchronizer sleeve & hub assembly (3) using special tool and hammer, facing
long flange side of hub to 3rd gear.
NOTE
• While press-fitting sleeve & hub, make sure that synchronizer 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.

Special tool
(B): 09913–84510
7) Install circlip (1) and confirm that circlip is installed in
groove securely. Install needle bearing (2) of resin
cage type, apply oil to it and then install synchronizer
ring (3) and 4th gear (4).
[A]: 3rd gear side D: Key way
C: Long flange E: Projecting end
I3RM0B521022-01
(A)
1
2
I4RH01520031-01
[A]: 3rd gear side B: Long flange
A: Key way C: Projecting end
5. Input shaft
I3RM0B521023-01
I2RH01520052-01

Downloaded from www.Manualslib.com manuals search engine 5B-28 Manual Transmission/Transaxle:
8) Press-fit left bearing (2) using special tool and hammer.
Special tool
(A): 09913–70123
9) Using the same special tool at Step 8), drive in 5th
gear spacer (1).
CAUTION!
To prevent 5th gear spacer from being
distorted because of excessive compression,
do not press-fit it with left bearing at once.

Countershaft Assembly Disassembly and
Reassembly
S7RS0B5206020
Disassembly
1) Drive out left bearing cone (2) with 4th gear (3) from countershaft (1) using bearing puller (4) and
hydraulic press.
CAUTION!
• Use bearing puller and hydraulic press that will bear at least 5 ton (11,000 lb) safely.
• To avoid tooth damage, support 4th gear at flat side of bearing puller.

2) Apply bearing puller (5) to 2nd gear (4) and drive out 3rd & 4th gear spacer (2) and 3rd gear (3) together
with 2nd gear from countershaft (1) using hydraulic
press. Take out needle bearing from countershaft.
CAUTION!
• If compression exceeds 5 ton (11,000 lb), release compression once, reset bearing
puller support and then continue press
work again.
• To avoid gear tooth from being damaged, support it at flat side of bearing puller.

3) Take out 2nd gear synchronizer outer ring, center cone and inner ring.
4) Using snap ring pliers (2), remove circlip (1).
I4RH01520032-01
I2RH01520054-01
2. Low speed synchronizer sleeve
I2RH01520055-01
I6RS0C520014-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-29
5) Apply bearing puller (3) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (1)
with 1st gear using hydraulic press.
CAUTION!
To avoid gear tooth from being damaged,
support it at flat side of bearing puller.

6) Disassemble low speed synchronizer sleeve & hub assembly.
7) Take out 1st gear needle bearing from shaft.
8) Remove right bearing cone (2) using bearing puller (3), metal stick (1) and hydraulic press.
Reassembly 1) Clean all components thor oughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) To ensure lubrication of countershaft (1), air blow oil holes (2) and make sure that they are free from any
obstruction. 3) Fit low speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
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.

Synchronizer key installation position
A = B
4) Install right bearing cone (1) to countershaft (2) using special tool and hammer.
Special tool
(A): 09923–78210
I2RH01520057-01
I2RH01520058-01
I2RH01520060-01
[A]: 1st gear side D: Short flange
C: Key way
I3RM0A520051-01
I2RH01520062-01

Downloaded from www.Manualslib.com manuals search engine 5B-30 Manual Transmission/Transaxle:
5) Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring.
6) Drive in low speed synchronizer sleeve & hub assembly (1) using special tools and hammer.
NOTE
• Support shaft with special tool as shown in figure so that retainer of bearing cone (4)
will be free from compression.
• 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.

Special tool
(A): 09923–78210
(B): 09940–51710
(C): 09924–07730
(D): 09924–07710
7) Install circlip (1) and confirm that circlip is installed in groove securely.
Install needle bearing (2), apply oil to bearing.
With synchronizer outer ring (3), center cone (4) and
inner ring (5) put together and installed to 2nd gear
(6) as shown in figure. 8) Press-fit 3rd gear (2) and spacer (1) using special
tools and hydraulic press.
CAUTION!
Press-fit spacer (1) and 3rd gear (2) first, and
then 4th gear later separately so that
countershaft will not be compressed
excessively.

Special tool
(A): 09923–78210
(D): 09913–84510
9) Press-fit 4th gear (2) using the same procedure as Step 8).
10) Install left bearing cone (1) using special tools and hammer.
NOTE
For protection of right bearing cone (3),
always support shaft with special tool as
shown in figure.

Special tool
(A): 09923–78210
(E): 09913–80113
[A]: Section A – A
I4RH01520057-01
I2RH01520064-01
3. 2nd gear
I2RH01520065-01
I2RH01520066-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-31
Synchronizer Parts InspectionS7RS0B5206021
Check clearance “a” between synchronizer ring (2) and
gear (1), each chamfered tooth of gear, synchronizer
ring and sleeve, then determine parts replacement.
Clearance “a” between synchronizer ring and gear
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)Put the 2nd gear 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 “b” between synchronizer outer ring and
inner ring
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)
Gear Shift Shaft ComponentsS7RS0B5206022
I2RH01520048-01
I2RH01520059-01
5
3
4 6
1
2
8
7
77
(a)
(b)
(a)
(a)
I4RS0A520015-01
1. Low speed gear shift shaft
5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
2. High speed gear shift shaft 6. 5th gear shift fork : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
3. 5th & reverse gear shift shaft 7. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
4. 5th & reverse gear shift guide shaft 8. Shift fork bolt
: Apply thread lock 99000-32110 to bolt thread.

Downloaded from www.Manualslib.com manuals search engine 5B-32 Manual Transmission/Transaxle:
5th and Reverse Gear Shift Shafts Disassembly
and Assembly
S7RS0B5206023
Disassembly
Disassemble component parts using special tool and
hammer.
Special tool
(A): 09922–85811
Assembly
Replace or correct parts as required and assemble
shafts making sure that component parts are in proper
order as shown.
NOTE
• Distinguish reverse gear shift arm spring (Blue) (2) from low speed locating spring
(Yellow).
• Install 2 steel balls (3) in reverse gear shift arm (1) without fail.
• Drive in spring pin for reverse gear shift arm facing slit A toward 5th gear side.

Gear Shift Shaft and Fork InspectionS7RS0B5206024
Using feeler gauge, check clearance between fork (1)
and sleeve (2) and replace those parts if it exceeds limit.
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Service limit “a”: 1.0 mm (0.039 in.)
Insert each gear shift shaft into case and check that it
moves smoothly. If it doesn’t, correct using oilstone,
reamer or the like.
A: Face pin slit toward 5th gear side
4. Spring pin
5. 5th & reverse gear shift shaft
6. 5th & reverse gear shift yoke
7. 5th & reverse gear shift guide shaft
8. 5th gear side
I3RM0A520053-01
I2RH01520068-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-33
Differential ComponentsS7RS0B5206025
Differential Disassembly and AssemblyS7RS0B5206026
Disassembly1) Using special tools, remove right bearing (1).
Special tool
(A): 09913–60910
(B): 09925–88210 2) Remove left bearing in the same manner at Step 1).
3) Support differential case with soft jawed vise and
remove final gear bolts then take out final gear.
4) Using special tool and hammer, drive out differential pinion shaft pin and then disassemble component
parts.
Special tool
(C): 09922–85811
1. Differential pinion washer 8. Final gear
2. Differential side pinion gear 9. Final gear bolt
3. Differential side gear 10. Differential pinion shaft
4. Side gear washer : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
5. Differential side bearing : Do not reuse.
6. Differential pinion shaft pin : Apply transaxle oil.
7. Differential case
I6RS0C520007-01
1(B)
(A)
I5JB0A321013-02
1. Differential case
2. Differential gear
3. Differential pinion shaft
IYSY01521077-01

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly. Make sure that all parts are clean.
1) Assemble differential gear and measure thrust play
of differential gear as follows.
Special tool
(A): 09900–20607
(B): 09900–20701
Differential gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
1. Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top
surface of gear (2).
2. Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.
Right side
1. Using similar procedure to the left side, set dial gauge tip to gear (2) shoulder.
2. Move gear up and down by hand and read dial gauge.
2) If thrust play is out of sp ecification, select suitable
thrust washer from among the following available
size, install it and check again that specified gear
play is obtained.
Available thrust washer thickness
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 left bearing (2) using special tool and copper hammer.
Special tool
(A): 09913–76010
5) Support differential assembly (1) as illustrated so as to left bearing is floating , and then press-fit right
bearing (3) using special tools.
Special tool
(A): 09913–76010
(B): 09951–16060
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.90 mm (0.035 in.) 1.10 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.00 mm (0.039 in.)
[A]: Left side
[B]: Right side
I3RH0A520083-01
1
(A)
3
2 (B)
I6RS0C520008-01