2005 SUZUKI SWIFT Differential bolt

Downloaded from www.Manualslib.com manuals search engine 5A-148 Automatic Transmission/Transaxle:
One-way clutch No.1 assembly1) Install one-way clutch No.1 assembly (2) to rear planetary sun gear subassembly (1).
2) Securing rear planetary sun gear subassembly, ensure that one-way clutch No.1 assembly rotates
only in one direction.
If the one-way clutch rotates in both directions or it
does not rotate in either direction, replace it with new
one.
Adjustment
Differential side bearing preload 1) After applying A/T fluid to differential assembly, fit it to transaxle case.
2) Install torque converter housing to transaxle case, then tighten bolts (1) to specified torque.
Tightening torque
Torque converter housing bolt (a): 29 N·m (2.9
kgf-m, 21 lb-ft) 3) Measure bearing preload (a) by using a special tool.
Special tool
(A): 09928–06050
Differential side bearing preload (a) measured as
starting torque
In the case of new bearing: 0.78 – 1.37 N ⋅m (7.9 –
13.9 kg-cm, 0.58 – 1.01 lb-ft)
In the case of reused bearing: 0.39 – 0.69 N ⋅m
(3.9 – 6.9 kg-cm, 0.29 – 0.51 lb-ft)
4) If bearing preload is out of specification, select shim with suitable thickness from among the list below
and replace it. Then adjust differential side bearing
preload within specification.
Available shim thickness
NOTE
Record measured differential side bearing,
because it is necessary to adjust
countershaft bearing preload.

5) Remove differential assembly.
I2RH0B510254-01
I2RH0B510255-01
Thickness Identification mark
1.80 mm (0.070 in.) A
1.85 mm (0.072 in.) B
1.90 mm (0.074 in.) C
1.95 mm (0.076 in.) D
2.00 mm (0.078 in.) E
2.05 mm (0.080 in.) F
2.08 mm (0.081 in.) G
2.11 mm (0.083 in.) H
2.14 mm (0.084 in.) J
2.17 mm (0.085 in.) K
2.20 mm (0.087 in.) L
2.23 mm (0.088 in.) M
2.26 mm (0.089 in.) N
2.29 mm (0.090 in.) P
2.32 mm (0.091 in.) Q
2.35 mm (0.092 in.) R
2.40 mm (0.094 in.) S
2.45 mm (0.096 in.) T
2.50 mm (0.098 in.) U
2.55 mm (0.100 in.) V
2.60 mm (0.102 in.) W
2.65 mm (0.104 in.) X
2.70 mm (0.106 in.) Y
I2RH0B510256-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-149
Countershaft bearing preload1) After applying A/T fluid to countershaft assembly (1) and differential assembly (2), fit them.
2) Install torque converter housing to transaxle case, then tighten bolts to specified torque.
Tightening torque
Torque converter housing bolt: 29 N·m (2.9 kgf-
m, 21 lb-ft)
3) Measure bearing preload (b) by using special tool. Special tool
(A): 09928–06050
Countershaft bearing preload (b) measured as
starting torque
In the case of new bearing: 0.33 – 0.96 N⋅ m (3.3 –
9.8 kg-cm, 0.24 – 0.69 lb-ft)
In the case of reused bearing: 0.17 – 0.38 N ⋅m
(1.7 – 3.8 kg-cm, 0.12 – 0.28 lb-ft) 4) If bearing preload is out of specification, select shim
with suitable thickness from among the list below
and replace it. Then adjust countershaft bearing
preload within specification.
Available shim thickness
5) Remove differential assembly and countershaft assembly.
Countershaft bearing
preload =(b) – Differential side bearing
preload (a)
I2RH0B510257-01
I3RM0B510067-01
Thickness Identification mark
1.70 (0.066 in.) 1
1.75 (0.068 in.) 2
1.80 (0.070 in.) 3
1.85 (0.072 in.) 4
1.90 (0.074 in.) 5
1.93 (0.075 in.) 6
1.96 (0.077 in.) 7
1.99 (0.078 in.) A
2.02 (0.079 in.) B
2.05 (0.080 in.) C
2.08 (0.081 in.) D
2.11 (0.083 in.) E
2.14 (0.084 in.) F
2.17 (0.085 in.) G
2.20 (0.086 in.) H
2.25 (0.088 in.) K
2.30 (0.090 in.) L
2.35 (0.092 in.) M
2.40 (0.094 in.) N
2.45 (0.096 in.) P
2.50 (0.098 in.) Q
2.55 (0.100 in.) R
2.60 (0.102 in.) S
2.65 (0.104 in.) U
2.70 (0.106 in.) W

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-159
47) Install transaxle rear cover assembly on transaxle case.
48) Install hook (2) to location shown in figure.
49) Tighten rear cover bolts (1).
Tightening torque
Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
50) Install fluid reservoir LH plate (1). Tightening torque
Fluid reservoir LH plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
51) After applying A/T fluid to new governor apply No.2 gasket (1), install it to transaxle case. 52) After applying A/T fluid to differential assembly (1)
and countershaft assembly (2), install them to
transaxle case.
53) After applying A/T fluid to di rect clutch hub (1), install
it to planetary gear assembly.
54) After applying A/T fluid to input shaft rear thrust
bearing (1) and thrust bearing race (2), install them
into direct clutch hub (3).
I3RM0B510068-01
I2RH0B510303-01
I2RH0B510304-01
1
2
I4RS0A510036-01
I2RH0B510306-01
I2RH0B510307-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-167
Specifications
Tightening Torque SpecificationsS7RS0B5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
A/T fluid drain plug 171.7 12.5 ) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor bolt 131.3 9.5 ) / )
Input shaft speed sensor bolt 5.5 0.55 4.0)
Valve body harness connector bolt 7.00.7 5.0 )
Shift solenoid bolt 111.1 8.0 )
Oil strainer bolt 101.0 7.5 ) / )
Oil pan bolt 7.00.7 5.0 ) / )
Transaxle and engine fastening bolt and nut 85 8.5 61.5)
Drive plate to torque converter bolt 252.5 18.0 )
Transaxle stiffener bolt 555.5 40)
Starter motor bolt and nut 505.0 36.5 )
Oil pump subassembly bolt 101.0 7.5 )
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 111.1 8.0 )
Final gear bolt 787.8 56.5 )
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 292.9 21) / ) / )
Manual detent spring bolt 101.0 7.5 )
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 252.5 18.0 )
Fluid reservoir LH plate bolt 101.0 7.5 )
Oil pump assembly bolt 252.5 18.0 )
Transaxle case plug 7.5 0.75 5.5)
Valve body harness connector bolt 5.5 0.55 4.0)
Valve body bolt 111.1 8.0 )
Fluid outlet union 252.5 18.0 )
Fluid cooler pipe union bolt 222.2 16.0 )
Fluid cooler pipe bracket bolt 101.0 7.5 )
Fluid filler tube bolt 101.0 7.5 )
Input shaft speed sensor bolt 111.1 8.0 )
Harness bracket bolt 232.3 17.0 )
Select cable clamp bolt 101.0 7.5 )
Transmission range sensor lock nut 70.7 5.0 )
Manual select lever nut 131.3 9.5 )
Engine mounting LH bracket bolt 555.5 40.0
)

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-1
Transmission / Transaxle
Manual Transmission/Transaxle
General Description
Manual Transaxle Construction and ServicingS7RS0B5201001
The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs and three shafts
(input shaft, countershaft and reverse gear shaft). All forward gears are in constant mesh, and reverse uses a sliding
idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is don e on input shaft and engaged with input shaft 3rd gear or
4th gear. The 5th speed synchronizer sleev e & hub on input shaft is engaged with input shaft fifth gear mounted on the
input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used.
The device utilizes the 5th synchromesh, which is the lever synchro type, to appl y the brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of
shifting to 2nd gear.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
For servicing, it is ne cessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tight ened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.
Further, care must be taken to adjust preload of count ershaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

Downloaded from www.Manualslib.com manuals search engine 5B-10 Manual Transmission/Transaxle:
16) Remove engine under covers.
17) Support transaxle with transmission jack.
18) Remove transaxle to engine bolts and nut of lower side.
19) Remove engine left mounting (1) with bracket (2).
20) Remove engine rear mounting bracket bolts (1).
21) Remove other attached parts from transaxle, if any.
22) Pull transaxle so as to disconnect input shaft from clutch disc, and then lower it. Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer when installing it into differential gear.

Reverse dismounting procedure for remounting noting
the following.
• Tighten each bolts and nuts to specified torque referring to “Manual Transaxle Unit Components”.
• Set each clamp for wiring securely.
• Fill transaxle oil referring to “Manual Transaxle Oil
Change”.
• Fill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
• Install hook (1) and ground cable (2) at specified position as shown in figure.
• Connect battery and check function of engine, clutch
and transaxle.
1
2
I4RS0A520021-01
1
I4RS0A520022-01
3. Transaxle side cover 4. Transaxle left case
90
1
2 3
4
I4RS0A520023-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-13
Manual Transaxle Assembly ComponentsS7RS0B5206013
I6RS0C520005-01
1. Transaxle right case 24. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case : Apply sealant 99000-31260 to mating surface of left case and right
case. 25. 5th gear shift fork
3. Gear shift and select shaft assembly 26. Needle bearing
4. Transaxle left case plate 27. Input shaft 5th gear
5. Transaxle side cover : Apply sealant 99000-31260 to mating surface of side cover and left
case. 28. Reverse gear shift lever
6. Back up light switch 29. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring 30. Reverse gear shaft
8. Differential assembly 31. Washer
9. Oil level/filler plug : Apply sealant 99000-31260 to all around thread part of plug. 32. Reverse idler gear
10. Oil drain plug : Apply sealant 99000-31260 to all around thread part of plug. 33. Reverse shaft bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-21
c) Install differential side bearing shim to left case (4).
d) Apply oil to new O-ring of side bearing retainer (3), and install side bea ring retainer with new O-
ring to left case.
e) Tighten side bearing retainer bolts (1) to specified torque.
NOTE
Install side bearing retainer with its punch
mark (2) facing upward.

Tightening torque
Side bearing retainer bolt (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
10) Check locating springs (2, 4 and 5) for deterioration and replace with new one as necessary.
Locating spring
11) Install steel balls (3) and locating springs (2, 4 and 5) for respective gear shift shaft and tighten bolts (1) to
which sealant has been applied.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift locating bolt (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
12) Install new snap ring (1) using snap ring pliers (2).
13) To seat countershaft left bearing outer race (1) to bearing cone, and tap countershaft left bearing outer
race (1) using special tool and plastic hammer (2).
Special tool
(A): 09913–70123
Locating spring free
length
Standard Service limit
Low speed (2) 53.1 mm
(2.091 in.) 50.5 mm
(1.988 in.)
High speed (4) 45.9 mm
(1.807 in.) 44.0 mm
(1.732 in.)
5th & reverse (5) 29.9 mm
(1.777 in.) 28.5 mm
(1.122 in.)
1, (a)
2
4
3
I4RS0A520039-01
2. Input shaft 3. Input shaft left bearing
I2RH01520084-01
1
2
2
3
I6RS0C520012-01
I3RM0A520030-01