2005 SUZUKI SWIFT gear repair

Downloaded from www.Manualslib.com manuals search engine 5A-28 Automatic Transmission/Transaxle:
3 → 4 upshift fails to
occur Malfunction of shift solenoid valve-B
Inspect. If NG, replace.
Malfunction of “3” position switch Inspect. If NG, replace.
Malfunction of engine coolant
temperature sensor Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of input shaft speed sensor Inspect. If NG, replace.
Malfunction of throttle position sensor Inspect. If NG, replace.
Malfunction of transmission range
sensor Inspect. If NG, replace.
Malfunction of crankshaft position
sensor Inspect. If NG, replace.
Malfunction of timing solenoid valve Inspect. If NG, replace.
Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Faulty O/D and 2nd coast brake Inspect. If NG, replace.
Gear shift point is
incorrect Abnormal engine condition
Inspect and repair engine.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of throttle position sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve Inspect. If NG, replace valve body assembly.
O/D
→ 3 downshift fails to
occur Malfunction of shift solenoid valve-A
Inspect. If NG, replace.
Malfunction of “3” position switch Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of input shaft speed sensor Inspect. If NG, replace.
Malfunction of throttle position sensor Inspect. If NG, replace.
Malfunction of timing solenoid valve Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Faulty forward clutch Inspect. If NG, replace.
3
→ 2 downshift fails to
occur Malfunction of shift solenoid valve-A
Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of throttle position sensor Inspect. If NG, replace.
Faulty valve body component Replace valve body assembly.
Faulty one-way No.1 clutch Inspect. If NG, replace.
2
→ 1 downshift fails to
occur Malfunction of shift solenoid valve-B
Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of throttle position sensor Inspect. If NG, replace.
Faulty valve body component Replace valve body assembly.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-31
Troubleshooting
Time Lag TestS7RS0B5104015
This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range an d measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from “N” to “R” range.
Gear shifting time lag
“N” → “D”: Less than 0.7 sec.
“N” → “R”: Less than 1.2 sec.
NOTE
• When repeating this test, be sure to wait at least one minute after select lever is shifted back to “N”
range.
• Engine should be warmed up fully for this test.
• Repeat test 3 times and take average of those data for final time lag data.

Condition Possible cause Correction / Reference Item
Lower than standard level
in both “D” and “R” range Engine output torque failure
Inspect and repair engine.
Faulty one-way clutch of torque
converter Replace torque converter.
Higher than standard
level in “D” range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Slippery forward clutch Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Leakage from “D” range fluid pressure
circuit Replace valve body assembly.
Higher than standard
level in “R” range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Slippery reverse clutch Inspect. If NG, replace.
Slippery 1st and reverse brake Inspect. If NG, replace.
Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
Higher than standard
level in both “D” and “R”
range Malfunction of pressure control solenoid
valve (Low line pressure)
Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Clogged oil strainer Replace.
Faulty oil pump Inspect. If NG, replace.
Leakage from both “D” and “R” range
fluid pressure circuit Replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine 5A-34 Automatic Transmission/Transaxle:
A/T Symptom DiagnosisS7RS0B5104018
Trouble Diagnosis 1
Electrical repair
Condition Possible cause Correction / Reference Item
Excessive shift shock Shift solenoid valve-A and/or -B circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faulty only
when N → D or 3 ↔ 4 shifting Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
Crankshaft position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “DTC P0335: Crankshaft Position
(CKP) Sensor “A” Circuit in Section 1A”. If NG,
repair.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
No gear shift as 3rd gear Shift solenoid valve-A and/or -B circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
TCM Substitute a known-good TCM and recheck.
Poor 1
→ 2 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-35
Poor 2 → 3 shiftShift solenoid valve-A circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
Poor 3
→ 4 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
Engine coolant temperature sensor
circuit faulty Inspect circuit for open, short and intermittent
referring to “DTC P0117: Engine Coolant
Temperature Circuit Low
in Section 1A” and/or
“DTC P0118: Engine Coolant Temperature
Circuit High in Section 1A”. If NG, repair.
Crankshaft position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “DTC P0335: Crankshaft Position
(CKP) Sensor “A” Circuit in Section 1A”. If NG,
repair.
“3” position switch circuit faulty Refer to “No Gear Shift to 4th gear”.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 5A-36 Automatic Transmission/Transaxle:
Poor 4 → 3 shiftShift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
“3” position switch circuit faulty Refer to “No Gear Shift to 4th gear”.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
Poor 3
→ 2 shift Shift solenoid valve-A circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
Poor 2
→ 1 shift Shift solenoid valve-A circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
Incorrect gear shift point Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 5A-40 Automatic Transmission/Transaxle:
Trouble Diagnosis 3
Off-vehicle repairNon operate TCC (lock-
up) system
Malfunction of TCC solenoid valve
Inspect. If NG, replace.
Malfunction of shift solenoid valve-A
and/or -B Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of input shaft speed sensor Inspect. If NG, replace.
Malfunction of transmission range
sensor Inspect. If NG, replace.
Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve Inspect. If NG, replace valve body assembly.
Malfunction of throttle position sensor Inspect referring to “Electric Throttle Body
Assembly On-Vehicle Inspection in Section
1C”. If NG, replace.
Malfunction of engine coolant
temperature sensor Inspect referring to “ECT Sensor Inspection in
Section 1C”. If NG, replace.
Malfunction of brake light switch Inspect referring to “Brake Light Switch
Inspection in Section 9B”. If NG, replace.
Faulty valve body component Replace valve body assembly.
Excessive “N”
→ “D” or
“N”
→ “R” time lag Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Pressure control solenoid valve circuit
faulty Inspect. If NG, replace valve body assembly.
Clogged oil strainer Replace.
Faulty valve body component Replace valve body assembly.
Condition Possible cause Correction / Reference Item
Condition
Possible cause Correction / Reference Item
Unable to run in all range Faulty oil pump Inspect. If NG, replace.
Seized or broken planetary gear Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Damaged drive plate Inspect. If NG, replace.
Faulty forward clutch Inspect. If NG, replace.
Faulty reverse clutch Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Faulty torque converter Replace.
Excessive “N”
→ “D” shift
shock Faulty forward clutch
Inspect. If NG, replace.
Excessive “N”
→ “R” shift
shock Faulty reverse clutch
Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Poor 1
→ 2 shift,
excessive shock or
slippage Faulty 2nd brake
Inspect. If NG, replace.
Faulty one-way No.1 clutch Inspect. If NG, replace.
Poor 2
→ 3 shift,
excessive shock or
slippage Faulty direct clutch
Inspect. If NG, replace.
Poor 3
↔ O/D shift,
excessive shock or
slippage Faulty forward clutch
Inspect. If NG, replace.
Faulty O/D and 2nd coast brake Inspect. If NG, replace.
Poor 3
→ 2 shift,
excessive shock or
slippage Faulty direct clutch
Inspect. If NG, replace.
Faulty one-way No.1 clutch Inspect. If NG, replace.
Poor 2
→ 1 shift,
excessive shock or
slippage Faulty 2nd brake
Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.

Downloaded from www.Manualslib.com manuals search engine 5A-52 Automatic Transmission/Transaxle:
DTC P0722: Output Speed Sensor Circuit No SignalS7RS0B5104028
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

3 Inspect input shaft speed sensor
1) Inspect input shaft speed sensor referring to “Input Shaft
Speed Sensor Inspection”.
Is result satisfactory? “WHT” or “BLK” circuit
open or short.
Replace input shaft
speed sensor.
4 Check visually input shaft speed sensor and direct
clutch drum for the following
• No damage
• No foreign material attached
• Correct installation
Are they in good condition? Intermittent trouble or
faulty TCM.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
If OK, substitute a
known-good TCM and
recheck.
Clean, repair or replace.
Step Action Yes No
I2RH0B510020-01
1. TCM
3. To ECM
2. Output shaft speed sensor [A]: Terminal arrangement of TCM connector (viewed from harness side)
DTC detecting condition Trouble area
No output shaft speed sensor signal is detected although
input shaft speed sensor signal s are detected while vehicle is
running at 5 km/h (3 mile/h) or more in vehicle speed with
“D”, “2” or “L” range. • Output shaft speed sensor or its circuit malfunction
• Damaged sensor gear (driven gear)
• Damaged output shaft speed sensor drive gear
•TCM
IG112V
PPLC35-25
2
C34
25
C35
[A]
1
BLK/RED
BLK/ORN
3
I4RS0B510005-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-3
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS7RS0B5204001
Repair Instructions
Manual Transaxle Oil ChangeS7RS0B5206001
1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil. 5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Pour new specified oil unt il oil level reaches bottom
of oil filler plug hole (3) as shown in figure.NOTE
It is highly recommended to use API GL-4
75W-90 gear oil.

Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Manual transaxle oil capacity
Reference: 2.0 liters (4.2/3.5 US/Imp. pt)
Condition Possible cause Correction / Reference Item
Gears slipping out of
mesh Worn shift fork shaft
Replace.
Worn shift fork or synchronizer sleeve Replace.
Weak or damaged locating springs Replace.
Worn bearings on input shaft or
countershaft Replace.
Worn chamfered tooth on sleeve and
gear Replace sleeve and gear.
Hard shifting Maladjusted gear select control cable Adjust.
Inadequate or insufficient lubricant Replenish.
Improper clutch pedal free travel Replace clutch master cylinder or clutch pedal
arm.
Distorted or broken clutch disc Replace.
Damaged clutch pressure plate Replace clutch cover.
Worn synchronizer ring Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve or gear.
Worn gear shift / select control cables
joint Replace.
Distorted shift shaft Replace.
Worn gear shift / select control cables Replace.
Noise Inadequate or insufficient lubricant Replenish.
Damaged or worn bearing(s) Replace.
Damaged or worn gear(s) Replace.
Damaged or worn synchronizer parts Replace.