2006 SUZUKI SWIFT engine cover

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.

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 5B-14 Manual Transmission/Transaxle:
Fifth Gear Disassembly and AssemblyS7RS0B5206014
Disassembly1) Remove cover bolts and take off transaxle side cover (1).
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using snap ring pliers, remove circlip (1).
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchron izer levers, synchronizer
ring and input shaft 5th gear (5) all together. Use
gear puller for removal if spline fitting of hub is tight. 5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
11. Sensor cap 34. Washer
12. Oil gutter bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 35. Side bearing retainer
13. Left case plate bolts : Apply thread lock 99000-32110 to all around thread part of bolt. 36. O-ring
14. Sensor cap bolt 37. Oil seal
: Apply grease 99000-25011 to oil seal lip.
15. Side cover bolts 38. Outer race
16. Transaxle case bolts 39. Breather hose
17. 5th speed synchronizer ring 40. Side bearing retainer bolt
18. 5th speed synchronizer lever : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
19. 5th speed synchronizer sleeve & hub : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
20. Circlip :10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
21. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
22. Countershaft 5th gear : Do not reuse.
23. Countershaft nut : After tightening nut to specified torque, caulk nut securely. : Apply transaxle oil.
I4RS0A520027-01
342
1
5
I4RS0A520028-01
1(A)
2
I3RM0B521014-01
I4RS0A520041-01

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
5) Fit 5th gear shift fork (1) to synchronizer sleeve (2) and hub (3) assembly and install them into input
shaft and gear shift shaft aligning punch mark (4)
with matching mark (5) on input shaft.
6) Tighten shift fork bolt (2) to which thread lock cement
has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
7) Using snap ring pliers, inst all new circlip (1) to input
shaft (3) in specified direction as shown in figure. 8) Clean mating surface of both left case (2) and side
cover (1), apply sealant to side cover (1) as shown in
figure by such amount t hat its section is 1.5 mm
(0.059 in.) in diameter, mate it with left case and then
tighten bolts to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Manual Transaxle Assembly Disassembly and
Reassembly
S7RS0B5206015
Disassembly
1) Remove gear shift and select shaft assembly referring to “Gear Shift an d Select Shaft Assembly
Removal and Installation”.
2) Remove fifth gear referring to “Fifth Gear Disassembly and Assembly”.
3) Remove left case plate.
4) Remove snap ring (1) using snap ring pliers (2).
4. Polished surface
I4RS0A520029-01
2, (a), “A”
1 33
4
1
I4RS0A520030-01
2. Input shaft 3. Input shaft left bearing
I4RS0A520031-01
1
2
2
3
I6RS0C520012-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-35
6) Hold differential assembly with soft jawed vise (3),
install final gear (2) as shown in figure and then
tighten bolts (1) to specified torque.
CAUTION!
Use of any other bolts than specified ones is
prohibited.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS7RS0B5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Leve r and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A520043-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Transaxle oil drain plug 21 2.1 15.5 )
Transaxle oil level / filler plug 21 2.1 15.5 )
Back up light switch 23 2.3 17.0 )
Gear shift guide case bolt 23 2.3 17.0 )
Select lever bracket bolt 23 2.3 17.0 )
Gear shift interlock bolt 23 2.3 17.0 )
5th to reverse interlock guide bolt 23 2.3 17.0 )
Countershaft nut 100 10.0 72.5 )
Shift fork bolt 10 1.0 7.5 )
Side cover bolt 10 1.0 7.5 )
Reverse gear shift lever bolt 23 2.3 17.0 )
Reverse shaft bolt 23 2.3 17.0 )
Transaxle case bolt 23 2.3 17.0 )
Side bearing retainer bolt 23 2.3 17.0 )
Gear shift locating bolt 13 1.3 9.5 )
Left case plate bolt 23 2.3 17.0 )
Oil gutter bolt 10 1.0 7.5 )
Final gear bolt 90 9.0 65.0 )

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-1
Transmission / Transaxle
Clutch
General Description
Clutch ConstructionS7RS0B5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positione d on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal c auses the release bearing to advance and pushes on the tips of the tapered fingers of
the diaphragm spring. When this happens, the diaphragm sp ring pulls the pressure plate away from the flywheel,
thereby interrupting the flow of drive from flywheel through clutch disc to transaxle input shaft. Clutch fluid is supplied
from brake fluid reservoir. Clutch fluid level can be checked by brake fluid level of brake fluid reservoir.
[A]: For petrol engine model2. Flywheel5. Clutch cover 8. Input shaft bearing
[B]: For diesel engine model 3. Clutch disc6. Diaphragm spring 9. Input shaft
1. Crankshaft 4. Pressure plate7. Release bearing 10. Release shaft
I4RS0A530001-01

Downloaded from www.Manualslib.com manuals search engine 5C-2 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS7RS0B5304001
Repair Instructions
Clutch Pedal InspectionS7RS0B5306001
Cylinder Push Rod Play “A”1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “A” as shown.
Push rod play
“A”: Max. 3 mm (0.12 in.)
2) If “A” is not within specification, replace master cylinder (3) or pedal arm (2). Clutch Pedal Free Travel “B”
1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“B” in figure.
Clutch pedal free travel
“B”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “B” is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.
Condition Possible cause Correction / Reference Item
Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel
surface Replace disc, clutch cover or flywheel.
Weakened diaphragm spring Replace clutch cover.
Master cylinder piston or seal cup not
returning Replace master cylinder.
Dragging clutch Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Weakened diaphragm spring, or worn
spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle
input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
Clutch vibration Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly on
input shaft bearing retainer Lubricate or replace input shaft bearing
retainer.
Wobbly clutch disc, or poor facing
contact Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel
surface Replace clutch cover or flywheel.
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
Noisy clutch Worn or broken release bearing Replace release bearing.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring
rattling Replace clutch cover.
Grabbing clutch Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.