2006 SUZUKI SWIFT Transmission disassembly

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-125
Direct Clutch Assembly Disassembly and
Reassembly
S7RS0B5106039
Disassembly1) Remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates.
2) Using special tool and hydraulic press, remove shaft snap ring (1).
Special tool
(A): 09926–98310
CAUTION!
Do not press direct clutch return spring
subassembly in over 0.7 mm (0.027 in.).
Excessive compression may cause damage
to direct clutch return spring subassembly
and/or piston.

3) Remove direct clutch re turn spring assembly (2).
4) Using a finger to block oil hole (1), apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2, 57 –
113 psi) to opposite hole, which will assist in removal
of the clutch piston. 5) Remove outer O-ring (1).
6) Remove inner O-ring (2).
7) Remove input shaft seal rings (1).
I2RH0B510162-01
I2RH0B510163-01
I2RH0B510164-01
2. Direct clutch piston
1. Input shaft subassembly
I2RH0B510165-01
I2RH0B510166-01
I2RH0B510167-01

Downloaded from www.Manualslib.com manuals search engine 5A-126 Automatic Transmission/Transaxle:
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal ring and O-ring. Apply A/T fluid before installation.
• Do not damage direct clutch return spring subassembly (1) and piston by pressing in direct
clutch return spring subassembly passing through its
original installing position over 0.7 mm (0.027 in.).
Special tool
(A): 09926–98310
• Apply A/T fluid to direct cl utch separator plates (4),
discs (3) and retaining plate (2).
• Install direct clutch separator plates (4), discs (3), retaining plate (2) and snap ring (1) to input shaft
subassembly.
• Install plate snap ring so that its both ends would be positioned in correct locations as shown in figure. • After assembly, measure direct clutch piston stroke.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
When piston stroke is out of specification, select direct
clutch retaining plate with suitable thickness from
among the following table and replace it.
Available direct clutch retaining plate thickness
I2RH0B510168-01
I2RH0B510169-01
[A]: Correct [B]: Incorrect
ThicknessIdentification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
2.8 mm (0.110 in.) 4
1. Direct clutch assembly 3. Oil hole
2. Oil pump assembly
I2RH0B510170-01
I2RH0B510171-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-129
Forward and Reverse Clutch Assembly
Preliminary Check
S7RS0B5106042
1) Install forward and reverse clutch assembly (1) to
transaxle rear cover (2), blow in compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) through oil
hole (4) of transaxle rear cover with the special tool
attached on the upper surf ace of reverse clutch
retaining plate (3), and measure reverse clutch
piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) through oil hole (1) of transaxle rear
cover with the special tool attached on the upper
surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Forward and Reverse Clutch Assembly
Disassembly and Reassembly
S7RS0B5106043
Disassembly
1) Remove reverse clutch plate snap ring (1) and take out reverse clutch retaini ng plate, discs, separator
plates and clutch cushion plate from intermediate
shaft subassembly.
2) Remove forward clutch plate snap ring (1) and take out forward clutch retaining plate, discs and
separator plates from forward clutch drum.
3) Remove balancer snap ring by using special tool and hydraulic press.
Special tool
(A): 09926–97610
CAUTION!
Do not press forward clutch return spring
subassembly in over 1.5 mm (0.059 in.).
Excessive compression may cause damage
to return spring subassembly and/or
balancer.

I2RH0B510176-01
I2RH0B510177-02
I2RH0B510178-01
I2RH0B510179-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-131
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Before assembling, apply automatic transaxle fluid to component parts.
• Replace O-rings and seal ring with new ones.
• Do not damage forward clutch return spring subassembly and balancer (1) by pressing forward
clutch return spring subassembly passing through its
original installing position over 1.5 mm (0.059 in.).
Special tool
(A): 09926–97610
• Apply A/T fluid to forward clutch separator plates (1), discs (2) and retaining plate (3).
• Install forward clutch separator plates (1), discs (2) and retaining plate (3), then snap ring (4) to forward
clutch drum. • Install forward clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
I2RH0B510180-01
4
1
2 3
I5RW0C510062-01
[A]: Correct
[B]: Incorrect
I2RH0B510188-01

Downloaded from www.Manualslib.com manuals search engine 5A-134 Automatic Transmission/Transaxle:
2nd Brake Piston Assembly ComponentsS7RS0B5106045
2nd Brake Piston Assembly Disassembly and
Reassembly
S7RS0B5106046
Disassembly1) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of 2nd brake cylinder (3)
to remove 2nd brake piston (2). 2) Remove inner O-ring (1) and outer O-ring (2).
I2RH0B510196-01
1. 2nd brake cylinder
3. Inner O-ring: Apply automatic transaxle fluid.
2. 2nd brake piston 4. Outer O-ring: Do not reuse.
I2RH0B510197-01
I2RH0B510198-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-135
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new O-rings. Apply A/T fluid to the O-rings, before installation.
• Install 2nd brake piston (1) to which A/T fluid is applied to 2nd brake cylinder (2).
Do not damage O-ring wh en installing 2nd brake
piston.
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly ComponentsS7RS0B5106047
I2RH0B510199-01
I2RH0B510200-01
1. Snap ring 5. O/D and 2nd coast brake piston 9. Rear cover plug O-ring
2. O/D and 2nd coast brake return spring subassembly 6. R ear cover seal ring: Apply automatic transaxle fluid.
3. O/D and 2nd coast brake piston front O- ring7. Transaxle rear cover : Do not reuse.
4. O/D and 2nd coast brake piston rear O- ring8. Rear cover plug : Tightening torque

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 Automatic Transmission/Transaxle: 5A-137
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal rings and O-rings. Apply A/T fluid to seal rings and O-rings before installation.
• Tighten rear cover plugs to specified torque.
Tightening torque
Rear cover plug: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
• Before installing rear cover seal ring, apply A/T fluid to ring.
First, tighten seal ring to 5 mm (0.197 in.), then install
seal ring.
• Do not open rear cover seal ring too wide to attach.
• Do not damage O/D and 2nd coast brake return spring subassembly and piston by pressing in O/D
and 2nd coast brake return spring subassembly
passing through its original installing position over 1.0
mm (0.039 in.).
Special tool
(A): 09926–96030
(B): 09946–06710Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Inspection
S7RS0B5106049
O/D and 2nd Coast Brake Return Spring
Subassembly
Measure free length of O/D and 2nd coast brake return
spring subassembly.
Free length of O/D and 2nd coast brake return spring
subassembly
“a”: 18.99 mm (0.748 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

Transaxle Rear Cover Bush
Measure transaxle rear cover bush bore by using special
tool.
If measured transaxle rear cover bush bore is out of
specifications, replace transaxle rear cover with new
one. In replacement, inte rmediate shaft subassembly
also needs to be checked. Replace intermediate shaft
subassembly, if necessary.
Special tool
(A): 09900–20605
Transaxle rear cover bush bore
Standard: 13.94 – 13.96 mm (0.549 – 0.550 in.)
1. Transaxle rear cover
1. Transaxle rear cover
I2RH0B510206-01
I2RH0B510201-01
I2RH0B510207-01
I2RH0B510208-01