2006 SUZUKI SWIFT check oil

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

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-4 Manual Transmission/Transaxle:
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Differential Side Oil Seal ReplacementS7RS0B5206002
1) Lift up vehicle and drain transaxle oil.
2) Remove front drive shaft and/or center shaft referring to “Front Driv e Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
4) Install oil seal (1) facing its spring side inward. Use special tool and hammer for installation.
Special tool
(A): 09913–85210
5) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make
sure of its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
6) Insert front drive shaft and/or center shaft referring to “Front Drive Shaft A ssembly Removal and
Installation in Section 3A”.
7) Fill transaxle oil as specified referring to “Manual Transaxle Oil Change”, and make sure that oil has
been sealed with oil seal.
I4RS0A520001-01
(A)
1
I4RH01520003-01
IYSY01520005-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-7
3) Apply grease to pin (5) of gear shift control lever, and then install adjuster (1) into pin of gear shift control
lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in the direction of A.
NOTE
At this time, do not a pply force in the cable
operation direction B to adjuster.

5) Slide lock plate (3) in the direction of C, until it gets over the claw (4) of cable end holder.
Back Up Light Switch Removal and InstallationS7RS0B5206006
Removal
1) Remove battery and tray with coolant reservoir.
2) Disconnect back up light switch coupler (1).
3) Remove back up light switch (2).
Installation 1) Apply oil to new O-ring (1) and tighten back up light switch (2) to specified torque.
Tightening torque
Back up light switch (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
2) Connect back up light switch coupler.
3) Install battery and tray, and then install coolant reservoir to battery tray.
Back Up Light Switch InspectionS7RS0B5206007
Check back up light switch for function using ohmmeter.
Back up light switch specification
Switch ON (Push): Continuity
Switch OFF (Release ): No continuity
3
3
41
2
A
C
1
B
5, “A”
I4RS0A520005-01
3. Gear shift and select shaft assembly
3
1
2
I4RS0A520010-01
1 2, (a)
I3RH0A520006-01
I4RS0A520011-01

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 5B-18 Manual Transmission/Transaxle:
18) Remove differential bearing shim.
19) Remove differential side bearing outer race from left case (1) using special tools.
Special tool
(A): 09924–74510
(B): 09926–27610
20) Remove differential gear assembly (1) from right case (2).
Reassembly 1) Install differential assembly (1) into right case (2). 2) Join input shaft assembly (5), countershaft assembly
(4), low speed gear shift shaft (2) and high speed
gear shift shaft (3) assemblies all together, then
install them into right case (1).
CAUTION!
Take care not to damage oil seal lip by input
shaft, or oil leakage may take place.

NOTE
• Input shaft right bearing on shaft can be
installed into right case tapping shaft with
plastic hammer.
• Check to make sure that countershaft is engaged with final g ear while installing.

3) Install 5th & reverse gear shift shaft (1) with 5th &
reverse gear shift guide shaft (2) into right case (5).
Reverse gear shift arm (4) has to be joined with
reverse gear shift lever (3) at the same time.
(A)
(B)
1
I4RS0A520035-01
I6RS0C520006-02
I6RS0C520006-02
I2RH01520080-01
I2RH01520081-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-21
c) Install differential side bearing shim to left case (4).
d) Apply oil to new O-ring of side bearing retainer (3), and install side bea ring retainer with new O-
ring to left case.
e) Tighten side bearing retainer bolts (1) to specified torque.
NOTE
Install side bearing retainer with its punch
mark (2) facing upward.

Tightening torque
Side bearing retainer bolt (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
10) Check locating springs (2, 4 and 5) for deterioration and replace with new one as necessary.
Locating spring
11) Install steel balls (3) and locating springs (2, 4 and 5) for respective gear shift shaft and tighten bolts (1) to
which sealant has been applied.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift locating bolt (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
12) Install new snap ring (1) using snap ring pliers (2).
13) To seat countershaft left bearing outer race (1) to bearing cone, and tap countershaft left bearing outer
race (1) using special tool and plastic hammer (2).
Special tool
(A): 09913–70123
Locating spring free
length
Standard Service limit
Low speed (2) 53.1 mm
(2.091 in.) 50.5 mm
(1.988 in.)
High speed (4) 45.9 mm
(1.807 in.) 44.0 mm
(1.732 in.)
5th & reverse (5) 29.9 mm
(1.777 in.) 28.5 mm
(1.122 in.)
1, (a)
2
4
3
I4RS0A520039-01
2. Input shaft 3. Input shaft left bearing
I2RH01520084-01
1
2
2
3
I6RS0C520012-01
I3RM0A520030-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-27
3) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to each key but it is assigned as sleeve & hub
assembly.
• Size of high speed synchronizer sleeve, hub, keys and springs is between those of
low speed and 5th speed ones.

Synchronizer key in stallation position
A = B
4) Drive in right bearing (1) to input shaft (2) using special tool and hammer.
Special tool
(A): 09951–16080
5) Install 3rd gear needle bearing, apply oil to it, then install 3rd gear (1) and synchronizer ring (2).
6) Drive in high speed synchronizer sleeve & hub assembly (3) using special tool and hammer, facing
long flange side of hub to 3rd gear.
NOTE
• While press-fitting sleeve & hub, make sure that synchronizer ring key slots are
aligned with keys in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press- fitting sleeve & hub assembly.
• Synchronizer rings for 3rd and 4th are identical.

Special tool
(B): 09913–84510
7) Install circlip (1) and confirm that circlip is installed in
groove securely. Install needle bearing (2) of resin
cage type, apply oil to it and then install synchronizer
ring (3) and 4th gear (4).
[A]: 3rd gear side D: Key way
C: Long flange E: Projecting end
I3RM0B521022-01
(A)
1
2
I4RH01520031-01
[A]: 3rd gear side B: Long flange
A: Key way C: Projecting end
5. Input shaft
I3RM0B521023-01
I2RH01520052-01