2005 SUZUKI SWIFT torque

Downloaded from www.Manualslib.com manuals search engine A u to m a tic Tra n s m is s io n /Tra n s a x le : 5 A -1 0 9
1. Torque converter37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing : Apply sealant 99000-31230 to mating
surface to transaxle case. 38. Cooler check valve
74. Rear sun gear thrust bearing race
3. Oil strainer assembly : Replace oil strainer when overhauling. 39. Spring
75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely. 84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal : Apply grease 99000-25030 to oil seal
lip. 49. Reduction drive gear
85. Rear cover seal ring
14. Differential side oil seal : Apply grease 99000-25030 to oil seal
lip. 50. Planetary ring gear subassembly
86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly 93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc : Do not reuse.
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Apply automatic transaxle fluid.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 23 N⋅m (2.3 kgf-m, 17 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 25 N⋅m (2.5 kgf-m, 18 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face. : 7.5 N
⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 22 N⋅m (2.2 kgf-m, 16 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 7 N⋅m (0.7 kgf-m, 5.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 17 N⋅m (1.7 kgf-m,12.5 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 29 N⋅m (2.9 kgf-m, 21 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-110 Automatic Transmission/Transaxle:
Automatic Transaxle Unit DisassemblyS7RS0B5106033
CAUTION!
• Thoroughly clean transaxle exterior before overhauling it.
• Keep working table, tools and hands clean while overhauling.
• Use special care to handle aluminum parts so as not to damage them.
• Do not expose removed parts to dust. Keep them always clean.

1) Remove torque converter (1).
CAUTION!
Remove torque converte r as much straight
as possible. Leaning it may cause to damage
oil seal lip.

2) Remove engine mounting LH bracket (1).
3) Remove manual select lever (1). 4) Uncaulk lock washer (1),
then remove lock nut (2)
and lock washer.
5) Remove transmission range sensor (1).
6) Remove output shaft speed sensor (2) and input shaft speed sensor (1).
7) Remove harness bracket (3) and select cable clamp (4).
I2RH0B510078-01
I3RM0B510054-01
1
I3RM0B510055-01
1
2
I3RM0B510056-01
I3RM0B510057-01
I3RM0B510058-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-113
19) Remove transaxle case plug (1).
20) Remove torque converter housing bolts.
21) Remove torque converter housing (1) while tapping
around it lightly with plastic hammer.
22) Remove breather hose (1).
23) Remove breather union (2).
24) Measure input shaft thrust play. Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
When input shaft thrust play is out of specification,
select input shaft front th rust bearing with proper
thickness from among the list below and replace it.
Special tool
(A): 09900–20607
(B): 09900-20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
Available input shaft front thrust bearing
thickness
: 3.45, 4.05 mm (0.136, 0.159 in.) 25) Remove oil pump assembly (1).
26) Remove direct clutch assembly (1).
27) Remove input shaft front thrust bearing (1).
NOTE
If input shaft front thrust bearing is not
found, it may have been taken out with oil
pump assembly.

I2RH0B510095-01
I3RM0B510060-01
1
2
I2RH0B510097-01
I2RH0B510098-01
I2RH0B510099-01
I2RH0B510100-01
I2RH0B510101-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-121
74) Remove manual detent spring (1).75) Remove manual shift shaft oil seal (1).
Oil Pump Assembly ComponentsS7RS0B5106034
I2RH0B510146-01I2RH0B510147-01
I2RH0B510148-01
1. Oil seal
: Apply grease 99000-25030 to oil seal lip. 5. Oil pump drive gear : Apply automatic transaxle fluid.
2. O-ring 6. Stator shaft assembly : Tightening torque
3. Oil pump body 7. Oil pump subassembly bolts : Do not reuse.
4. Oil pump driven gear

Downloaded from www.Manualslib.com manuals search engine 5A-122 Automatic Transmission/Transaxle:
Oil Pump Assembly Disassembly and
Reassembly
S7RS0B5106035
Disassembly1) Remove O-ring from pump body.
2) Remove 8 oil pump subassembly bolts (1) and stator shaft assembly (2).
3) Remove oil seal (1) using special tool. Special tool
(A): 09913–50121
Reassembly 1) Install new oil pump body oil seal (1). Use special tool and hammer to install it, and then
apply grease to its lip portion.
Special tool
(A): 09913–85210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C) 2) Install driven gear and drive gear to oil pump body
after applying A/T fluid.
3) Install stator shaft assembly to oil pump body and tighten 8 pump subassembly bolts (1) to
specification.
Tightening torque
Oil pump subassembly bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
4) After applying A/T fluid to new O-ring, install it to oil pump body.
5) Check drive gear for smooth rotation by using torque converter (1).
Oil Pump Assembly InspectionS7RS0B5106036
1) Check body clearance of driven gear (1).Push driven gear to one side of oil pump body (2).
Using a feeler gauge, m easure clearance between
driven gear and body. If clearance exceeds its
standard value, replace oil pump assembly.
Clearance between oil pump driven gear and oil
pump body
Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.)
2. Oil pump body
2. Oil pump body
2 1
I4RS0A510041-01
I2RH0B510150-01
I2RH0B510151-01
1, (a)
I4RS0A510042-01
1
I4RS0A510043-01
I2RH0B510154-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-123
2) Check tip clearance of both drive and driven gears.Using a feeler gauge, m easure clearance between
drive and driven gear tips. If clearance exceeds its
standard value, replace oil pump assembly.
Tip clearance between oil pump drive gear and
oil pump driven gear
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
3) Check side clearance of both gears. Using a straightedge (1) and a feeler gauge (2),
measure side clearance between gears and pump
body.
If clearance exceeds its standard value, replace oil
pump assembly.
Side clearance between gears and oil pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.0019 in.)
4) Using special tool, measure stator shaft bush (1) bore.
If measured stator shaft bush bore is out of
specifications, replace oil pump assembly with new
one.
Special tool
(A): 09900–20605
Stator shaft bush bore
Standard: 18.424 – 18.450 mm (0.7254 – 0.7264
in.) 5) Install direct clutch asse
mbly (1) to stator shaft
assembly (2), then ensure that direct clutch
assembly turns smoothly.
If unsmooth rotation or noise are found in oil pump
assembly, replace oil pump assembly with new one.
This check should also be done to input shaft
assembly and replace input shaft assembly if
necessary.
6) Using special tool, measure oil pump body bush bore.
If measured oil pump body bush (1) bore is out of
specifications, replace o il pump assembly with new
one. Torque converter also needs to be checked.
Replace torque converter, if necessary.
Special tool
(A): 09900–20605
Oil pump body bush bore
Standard: 38.113 – 38.138 mm (1.5005 – 1.5015
in.)
I2RH0B510155-01
I2RH0B510156-01
I2RH0B510157-01
I2RH0B510158-01
I2RH0B510159-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-135
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new O-rings. Apply A/T fluid to the O-rings, before installation.
• Install 2nd brake piston (1) to which A/T fluid is applied to 2nd brake cylinder (2).
Do not damage O-ring wh en installing 2nd brake
piston.
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly ComponentsS7RS0B5106047
I2RH0B510199-01
I2RH0B510200-01
1. Snap ring 5. O/D and 2nd coast brake piston 9. Rear cover plug O-ring
2. O/D and 2nd coast brake return spring subassembly 6. R ear cover seal ring: Apply automatic transaxle fluid.
3. O/D and 2nd coast brake piston front O- ring7. Transaxle rear cover : Do not reuse.
4. O/D and 2nd coast brake piston rear O- ring8. Rear cover plug : Tightening torque

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-137
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal rings and O-rings. Apply A/T fluid to seal rings and O-rings before installation.
• Tighten rear cover plugs to specified torque.
Tightening torque
Rear cover plug: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
• Before installing rear cover seal ring, apply A/T fluid to ring.
First, tighten seal ring to 5 mm (0.197 in.), then install
seal ring.
• Do not open rear cover seal ring too wide to attach.
• Do not damage O/D and 2nd coast brake return spring subassembly and piston by pressing in O/D
and 2nd coast brake return spring subassembly
passing through its original installing position over 1.0
mm (0.039 in.).
Special tool
(A): 09926–96030
(B): 09946–06710Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Inspection
S7RS0B5106049
O/D and 2nd Coast Brake Return Spring
Subassembly
Measure free length of O/D and 2nd coast brake return
spring subassembly.
Free length of O/D and 2nd coast brake return spring
subassembly
“a”: 18.99 mm (0.748 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

Transaxle Rear Cover Bush
Measure transaxle rear cover bush bore by using special
tool.
If measured transaxle rear cover bush bore is out of
specifications, replace transaxle rear cover with new
one. In replacement, inte rmediate shaft subassembly
also needs to be checked. Replace intermediate shaft
subassembly, if necessary.
Special tool
(A): 09900–20605
Transaxle rear cover bush bore
Standard: 13.94 – 13.96 mm (0.549 – 0.550 in.)
1. Transaxle rear cover
1. Transaxle rear cover
I2RH0B510206-01
I2RH0B510201-01
I2RH0B510207-01
I2RH0B510208-01