2005 SUZUKI SWIFT 250

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 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-145
Reassembly1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque
converter housing.
Tightening torque
Torque converter housing plug (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
2) Using special tools, assemble differential side RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
3) Using special tool, install countershaft RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
4) Using special tools, install new differential side oil seal to torque converter housing.
Special tool
(A): 09924–74510
(B): 09944–88220 Differential side oil seal installing depth
“a”: 2.6 – 3.6 mm (0.10 – 0.14 in.)
5) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
6) Install lubrication LH tube (1) and RH tube (2).
7) Install fluid reservoir RH plate (1) and lubrication tube clamp (2).
Tightening torque
Lubrication tube clamp bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
Fluid reservoir RH plate bolt (b): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
I2RH0B510242-01
(A)
(B)
I3RM0B510063-01
(B) (A)
I3RM0B510064-01
I2RH0B510245-02
I2RH0B510237-01
I2RH0B510246-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

I2RH0B510252-01
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01

Downloaded from www.Manualslib.com manuals search engine 5A-150 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS7RS0B5106060
CAUTION!
• Automatic transaxle consists of highly precise parts. As even flaw in 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 or brake discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before
assembly.
• Use 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 cut outs and are
installed in groove correctly.
• Do not use adhesive cements on gaskets and similar parts.
• Be sure to torque each bolt and nut to specification.

1) Install new manual shift sh aft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.5 – 1.5 mm (0.02 – 0.06 in.) 2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl ro d (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using spring pin remover with 3.5 mm (0.14 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
I2RH0B510258-01
I2RH0B510259-01
I2RH0B510260-01
I2RH0B510261-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-155
26) Apply A/T fluid to 2nd brake piston assembly (1), and align the projection of 2nd brake piston assembly
with the groove of transaxle case, then put together.
27) Install 2nd brake piston snap ring (1) by using special tool and hydraulic press.
CAUTION!
Do not damage 2nd brake piston assembly,
return spring subassembly, plates and discs
by pressing in 2nd brake assembly passing
through its original installing position over
0.4 mm (0.016 in.).

Special tool
(A): 09926–96050
28) After applying A/T fluid to front sun gear thrust bearing race (2), install it to front planetary sun gear
(1). 29) Apply A/T fluid to front planetary sun gear (1) and
install it to planetary gear assembly (2).
30) Install O/D and 2nd coast brake retaining plate snap ring (1).
CAUTION!
Be sure to install O/D and 2nd coast brake
retaining plate snap ring correctly in groove
of transaxle case.

31) After applying grease to slide contact face of planetary carrier thrust washer (1), install it to
planetary gear assembly.
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
I2RH0B510282-01
I2RH0B510283-01
I2RH0B510285-01
I2RH0B510286-01
I2RH0B510287-01
I2RH0B510288-01

Downloaded from www.Manualslib.com manuals search engine 5A-166 Automatic Transmission/Transaxle:
91) Bend dents of lock washer (1) in order to prevent displacement of lock washer.
92) Install manual select lever (1). Tightening torque
Manual select lever nut (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
93) Install engine mounting LH bracket (1). Tightening torque
Engine mounting LH bracket bolt (a): 55 N·m (
5.5 kgf-m, 40.0 lb-ft) 94) Install torque converter (3) noting the following
points.
CAUTION!
• Before installing converter, make sure that its pump hub portion is free from nicks,
burrs or damage which may cause oil seal
to leak.
• Be very careful not to drop converter on oil pump gear. Damage in gear, should it
occur, may cause a critical trouble.

• Install torque converter aligning grooves (1) of torque converter and projection (2) of oil pump
drive gear.
• Install torque converter, using care not to damage oil seal of oil pump.
• After installing torque converter, check that distance “a” is within specification.
Torque converter installing position
“a”: More than 19.9 mm (0.783 in.)
• Check torque converter for smooth rotation.
• Apply grease around cup (6) at the center of torque converter.
“C”: Grease 99000–25011 (SUZUKI Super
Grease A)
1
I3RM0B510075-01
1
(a)
I3RM0B510076-01
I3RM0B510077-01
4. Flange nut 5. Torque converter housing
I2RH0B510337-01