2005 SUZUKI SWIFT drive shaft

Downloaded from www.Manualslib.com manuals search engine 5A-86 Automatic Transmission/Transaxle:
Reference waveform No. 5
Output shaft speed sensor signal at vehicle speed 60
km/h (37 mile/h).
TCM Power and Ground Circuit CheckS7RS0B5104046
Wiring DiagramMeasurement
terminal
CH1: “C35-25” to “C34-1”
Oscilloscope
setting CH1: 5 V/DIV
TIME: 2 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Drive vehicle at 60 km/h (37 mile/h).
I3RM0B510028-01
BLK
BLK
BLK
C34-1
C34-23
C34-6YEL/BLKYEL/BLU
LT GRN/BLK
+BB
C34-24WHT/RED1
23
6
24 23 1
C34C35
[A]
I4RS0A510023-01
1. TCM
3. Ignition switch
2. A/T relay [A]: Terminal arrangement of TCM connector (viewed from harness side)

Downloaded from www.Manualslib.com manuals search engine 5A-96 Automatic Transmission/Transaxle:
Output Shaft Speed Sensor Removal and
Installation
S7RS0B5106016
Removal
1) Disconnect negative cable at battery.
2) Disconnect output shaft speed sensor connector (2).
3) Remove output shaft speed sensor (1) by removing its bolt.
Installation 1) Apply A/T fluid to output shaft speed sensor O-ring.
2) Install output shaft speed sensor (1) to A/T case and tighten bolt to specified torque.
Tightening torque
Output shaft speed sensor bolt (a): 13 N·m (1.3
kgf-m, 9.5 lb-ft)
3) Connect output shaft speed sensor connector (2) to output shaft speed sensor (1).
4) Connect negative cable to battery.
Output Shaft Speed Sensor InspectionS7RS0B5106017
1) Connect positive cable of 12 volt battery to “A” terminal of sensor and ground cable to “C” terminal.
Then using voltmeter, check voltage between “B”
terminal and “C” terminal with output shaft speed
sensor driven gear rotated.
If measured voltage (pulse signal) is not as
specified, replace sensor.
Output shaft speed sensor output voltage
Pulse signal of alternating 0 – 1 V and 10 – 14 V 2) Check output shaft speed sensor driven gear (1) for
wear.
Replace if necessary.
Input Shaft Speed Sensor Removal and
Installation
S7RS0B5106018
Removal
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Remove input shaft speed sensor (1) by removing its bolt.
I3RM0B510040-01
I3RM0B510041-01
I2RH0B510045-01
I2RH0B510046-01
I2RH0B510047-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
Installation
Reverse removal procedure noting the following.
• Connect TCM connectors securely.
• If the vehicle is equipped with air bag system, be sure to enable air bag system after TCM is back in place.
Refer to “Enabling Air Bag System in Section 8B”.
A/T Relay InspectionS7RS0B5106027
1) Disconnect negative cable at battery.
2) Remove A/T relay (2) from fuse and relay box (1).
3) Check that there is no continuity between terminal “C” and “D”.
If continuity is indicated, replace A/T relay.
4) Connect battery positive (+ ) terminal to terminal “A”
of A/T relay and battery negative (–) terminal to
terminal “B” of A/T relay.
Check continuity between terminal “C” and “D” of A/T
relay.
If continuity does not indicated, replace A/T relay.
Differential Side Oil Seal ReplacementS7RS0B5106028
1) Lift up vehicle and drain automatic transaxle fluid.
2) Remove drive shaft joints from differential gear of transaxle. Refer to “Front Drive Shaft Assembly
Removal and Installation in Section 3A” for
procedure to disconnect drive shaft joints.
For differential side oil seal removal, it is not
necessary to remove drive shafts from steering
knuckle.
3) Remove differential side oil seal (1) by using screwdriver or the like.
"D"
"B" "A"
"C"
1
2
I6RS0C510012-01
I2RH0B510067-01

Downloaded from www.Manualslib.com manuals search engine 5A-104 Automatic Transmission/Transaxle:
4) Apply grease to new differential side oil seal lips.: Grease 99000–25030 (SUZUKI Super Grease C)
5) Install new differential side oil seals (1) by using special tool.
Special tool
(C): 09944–88220
(D): 09924–74510
Differential side oil seal installing depth
Right side “a”: 2.6 – 3.6 mm (0.10 – 0.14 in.)
Left side “b”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
6) Install drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”.
7) Pour A/T fluid referring to “A/T Fluid Change”.
A/T Fluid Cooler Hoses ReplacementS7RS0B5106029
The rubber hoses for the A/T fluid cooler should be
checked at specified interval. If replacing them, be sure
to note the following.
• to replace clamps at the same time
• to insert hose as far as its limit mark
• to clamp clamps securely
[A]: Right side [B]: Left side
I2RH0B510068-01
1. Inlet hose (Outlet from A/T fluid cooler)
2. Outlet hose (Inlet to A/T fluid cooler)
1 2I4RS0A510057-01

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-119
60) Remove snap ring while the 1st and reverse brake piston return springs are compressed using special
tool and hydraulic press.
CAUTION!
Do not press 1st and reverse brake return
spring subassembly in over 0.8 mm (0.031
in.).
Excessive compression may cause damage
to return spring subassembly, discs, plates
and/or piston.

Special tool
(A): 09926–97620
61) Remove 1st and reverse brake retaining plate, discs and separator plates.
62) Remove 1st and reverse brake return spring subassembly (1).
63) Turn over transaxle and uncaulk reduction drive gear nut (1). 64) Secure reduction drive gear (1) with parking lock
pawl, then remove reduction drive gear nut.
CAUTION!
• It is recommended that this operation should be carried out on rubber mat to
prevent damaging transaxle case.
• Never reuse removed nut.

65) Using special tools and hydraulic press, remove planetary ring gear subassembly (1).
CAUTION!
Do not reuse planetary ring gear
subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.

Special tool
(A): 09913–84510
(B): 09923–78210
66) Remove parking lock pawl shaft, then spring (2) and parking lock pawl (1).
I2RH0B510134-01
I2RH0B510135-01
I2RH0B510136-01
I2RH0B510137-02
I2RH0B510138-01
I2RH0B510139-01

Downloaded from www.Manualslib.com manuals search engine 5A-120 Automatic Transmission/Transaxle:
67) Screwing 3 bolts (1), remove reduction drive gear (2).
CAUTION!
Screw 3 bolts into reduction drive gear
uniformly, or reduction drive gear, bearing
and transaxle case may be damaged.

Bolt length
35 mm (1.38 in.)
68) Blowing compressed air from oil hole (1) of oil pump,
remove 1st and reverse brake piston (2). 69) Remove parking lock pawl bracket (1).
70) With slotted screwdriver, cut and unfold manual
valve lever spacer (1) and proceed to remove
manual valve lever spacer.
71) Using spring pin remover with 3.5 mm (0.14 in.) in diameter and hammer, drive out manual valve lever
pin (1).
72) Remove manual shift shaft (2).
73) Remove parking lock pawl rod (2) from manual valve lever (1).
I2RH0B510140-01
1 2I4RS0A510040-01
I2RH0B510142-01
I2RH0B510143-01
I2RH0B510144-01
I2RH0B510145-01

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