2006 SUZUKI SWIFT 400

Downloaded from www.Manualslib.com manuals search engine 5A-136 Automatic Transmission/Transaxle:
Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Disassembly and
Reassembly
S7RS0B5106048
Disassembly1) Remove snap ring by using special tools and hydraulic press.
Special tool
(A): 09926–96030
(B): 09946–06710
CAUTION!
Do not press O/D and 2nd coast brake return
spring subassembly in over 1.0 mm (0.039
in.).
Excessive compression may cause damage
to O/D and 2nd coast brake return spring
subassembly and/or piston.

2) Remove O/D and 2nd coast brake return spring assembly.
3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (2) of transaxle rear cover (1)
to remove O/D and 2nd coast brake piston. 4) Remove O/D and 2nd coast brake piston front O-ring
(1) and rear O-ring (2).
5) Remove rear cove r seal rings (1).
6) Remove rear cover plugs (1).
1. Transaxle rear cover
I2RH0B510201-01
I2RH0B510202-01
I2RH0B510203-01
I2RH0B510204-01
I2RH0B510205-01

Downloaded from www.Manualslib.com manuals search engine 5A-152 Automatic Transmission/Transaxle:
12) Install 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations
as shown in figure.
13) Using special tools, meas ure 1st and reverse brake
piston stroke when compressed air (400 – 800 kPa,
4 – 8 kg/cm
2, 57 – 113 psi) is brown through oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.791 – 1.489 mm (0.0311 – 0.0586 in.) 14) Install reduction drive gear (1) to transaxle case (3)
by using special tools and hydraulic press.
CAUTION!
• Do not use transaxle case as groundwork to press fit reduction drive gear.
• Do not give load more than 20 kN (2000 kg, 4410 lb) with hydraulic press. Otherwise, it
may result in damaging reduction drive
gear bearing.

NOTE
When replacing reduction drive gear, replace
it together with reduction driven gear as a
set.

Special tool
(A): 09951–18210
(B): 09944–78210
15) Install parking lock pawl (1) and spring (2). Apply A/T fluid to parking lock pawl sh aft, then insert it into
transaxle case.
[A]: Correct [B]: Incorrect
I2RH0B510268-01
I2RH0B510269-01
2. Stand that can slightly lift transaxle case.
I2RH0B510270-01
I2RH0B510271-01

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.

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.

Downloaded from www.Manualslib.com manuals search engine Steering General Diagnosis: 6A-2
Diagnostic Information and Procedures
Steering Symptom DiagnosisS7RS0B6104001
ConditionPossible cause Correction / Reference Item
Hard steering Tire not adequately inflated Inflate tires to proper pressure.
Malfunction of power steering system Check and correct.
Bind in tie-rod end ball studs or lower
ball joints Replace tie-rod end or front suspension arm.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Bind in steering column Repair or replace steering column.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Too much play in steering Wheel bearings worn Replace wheel bearing.
Loose steering gear case bolts Tighten gear case bolts.
Faulty steering gear case assembly Replace steering gear case assembly.
Worn steering shaft joints Replace joint.
Worn tie-rod ends or tie-rod inside ball
joints Replace tie-rod end or tie-rod.
Worn lower ball joints Replace front suspension control arm.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Poor return ability Bind in tie-rod end ball studs Replace tie-rod end.
Bind in ball joints Replace front suspension control arm.
Bind in steering column Repair or replace steering column.
Disturbed front end alignment Check and adjust front end alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Tires not adequately inflated Adjust tire pressure.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle) Loose steering gear case bolts
Tighten steering gear case bolts.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Faulty steering gear case assembly Replace steering gear case assembly.
Broken or other wise damaged wheel
bearing(s) Replace wheel bearing(s).
Wander or poor steering
stability Mismatched or uneven tires
Replace or inflate tires to proper pressure.
Loosen ball joints and tie-rod ends Replace suspension control arm or tie-rod end.
Faulty struts or mountings Replace strut or repair mounting.
Loose stabilizer bar Tighten or replace stabilizer bar or bush.
Broken or sagging springs Replace spring.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Erratic steering when
braking Worn wheel bearing(s)
Replace wheel bearing(s).
Broken or sagging spring(s) Replace coil spring(s).
Wheel tires are inflated unequally Inflate tires to proper pressure.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Brakes not working in unison Check and repair brake system.
Leaking caliper Repair or replace caliper.
Warped discs Replace brake disc.
Badly worn brake pads Replace brake pads.

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-2
Diagnostic Information and Procedures
Checking Steering Column for Accident
Damage
S7RS0B6204001
NOTE
Vehicles involved in accidents resulting in
body damage, where steering column has
been impacted or air bag deployed may have
a damaged or misaligned steering column.

Checking Procedure
NOTE
The steering column used in each vehicle is
one of the two types as shown.

1) Check that two capsules (1) are attached to steering column bracket securely. If found loose, replace
steering column assembly.
2) Take measurement “a”, “b” and “c” as shown. If it is shorter than spec ified length, replace steering
column assembly with new one.
Ty p e A
Power steering column length
“a”: 459 ± 2 mm (18.1 ± 0.08 in.)
“b”: 64.1 ± 1 mm (2.5 ± 0.03 in.)
“c”: 306.7 ± 1 mm (12.0 ± 0.03 in.)
Ty p e B
Power steering column length
“a”: 466 ± 2 mm (18.3 ± 0.08 in.)
“b”: 60.0 ± 1 mm (2.4 ± 0.03 in.)
“c”: 300.5 ± 1 mm (11.8 ± 0.03 in.) 3) Check steering shaft joints and shaft for any
damages such as crack, breakage, malfunction or
excessive play.
If anything is found faulty, replace as lower shaft
assembly or steering column assembly.
4) Check steering shaft for smooth rotation. If found defective, replace as steering column
assembly.
5) Check steering shaft and steering column for bend, cracks or deformation.
If found defective, replace.
[A]: Type A [B]: Type B
[A] [B]
1
1
1
1
I6RS0C620004-01
I6RS0C620001-01
I4RS0A620003-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-5
Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side)
Diagnostic Information and Procedures
EPS System CheckS7RS0B6304001
WARNING!
Carry out test drive in light traffic area to prevent an accident.

Refer to the following items for the details of each step.Terminal Circuit Terminal Circuit
E49-1 Main power supply for internal memory
and EPS motor E52-9 Ground for torque sensors
E49-2 Ground for P/S control module E52-10 —
E51-1 Motor output 1 E52-11 Serial communication for data link
connector
E51-2 Motor output 2 E52-12 Engine speed signal
E52-1 Ignition switch signal for P/S control
module E52-13 —
E52-2 — E52-14 P/S operation signal (idle up signal)
E52-3 — E52-15 —
E52-4 Vehicle speed signal E52-16 Torque sensor internal failure signal
E52-5 “EPS” warning light E52-17 —
E52-6 Torque sensor signal (Sub) E52-18 Torque sensor signal (Main)
E52-7 — E52-19 Ground for shield wire
E52-8 Main power supply for torque sensor E52-20 5 V reference power supply for torque
sensor
Step
Action YesNo
1 ) Customer complaint analysis
1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Was customer complaint analysis performed? Go to Step 2.
Perform customer
complaint analysis.
2 ) DTC check, record and clearance
1) Check for DTC (including pending DTC) referring to “DTC Check”, Record and Clearance.
Is there any DTC(s)? Print DTC or write them
down and clear them by
referring to “DTC
Clearance” and go to
St ep 3 .Go to Step 4.
3 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 5.
4 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 8.
5 ) Trouble symptom confirmation
1) Confirm trouble symptom referring to “Trouble Symptom Confirmation”.
Is trouble symptom identified? Go to Step 6.
Go to Step 7.
6 ) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 8.

Downloaded from www.Manualslib.com manuals search engine 6C-8 Power Assisted Steering System:
Step 2: DTC Check, Record and Clearance
First, check DTC, referring to “DTC Check”. If DTC is
indicated, print it or write them down and then clear them
by referring to “DTC Clearance”. DTC indicates
malfunction that occurred in the system but does not
indicate whether it exists now or it occurred in the past
and the normal condition has been restored now. To
check which case applies, check the symptom in
question according to Step 5 and recheck DTC
according to Step 6 and 7.
Attempt to diagnose a trouble based on DTC in this step
only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit
or difficulty in troubleshooting.
Step 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the P/S system
referring to “Visual Inspection”.
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis: ” and “S tep 2: DTC Check, Record
and Clearance: ”, confirm trouble symptoms. Also,
reconfirm trouble symptom by performing test drive and
turning steering wheel fully to right and left at stopped
vehicle.
Step 6 and 7: Rechecking and Record of DTC
Refer to “DTC Check” for checking procedure.
Step 8: Steering Symptom Diagnosis and P/S
System Symptom Diagnosis
Perform basic steering system check according to
“Steering Symptom Diagnosis in Section 6A” first. When
the end of the flow has been reached, check the parts of
the system suspected as a possible cause referring to
“P/S System Symptom Diagnosis” and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check)
and repair or replace faulty parts, if any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, P/S control module or other part and
repair or replace faulty parts.
Step 10: Intermittent Problems Check
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2. Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the P/
S system is free from any abnormal conditions. If what
has been repaired is related to the DTC, clear the DTC
once, perform DTC confirmation procedure and confirm
that no DTC is indicated.
“EPS” Warning Light CheckS7RS0B6304002
1) Turn ignition switch to ON position (without engine
running) and chec k if the “EPS” warning light (1)
lights up. If the light dose not light up, go to ““EPS”
Warning Light Does Not Come ON with Ignition
Switch Turned ON before Engine Starts” of the
diagnostic flows.
2) Start engine and check if the “EPS” warning light turns OFF. If light remains ON and no DTC is stored
in P/S control module, go to ““EPS” Warning Light
Remains ON Steady after Engine Starts” for
troubleshooting.
DTC CheckS7RS0B6304003
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
1
I6RS0C630002-01
(A)
1
I4RS0B450003-01