2006 SUZUKI SWIFT wheel

Downloaded from www.Manualslib.com manuals search engine 5A-32 Automatic Transmission/Transaxle:
Troubleshooting
Line Pressure TestS7RS0B5104016
Purpose of this test is to check operat ing conditions of each part by measuring fluid pressure in fluid pressure line.
Line pressure test requires the following conditions.
• Automatic fluid is at normal operating temperature (70 – 80 °C / 158 – 176 °F).
• Fluid is replenished to proper level (between FULL and LOW on dipstick).
• Air conditioner switch is turned OFF.
1) Apply parking brake securely and place chocks against wheels.
2) Remove fluid pressure check hole plug bolt.
3) Attach oil pressure gauge to fluid pr essure check hole in transaxle case.
Special tool
(A): 09925-37811-001
CAUTION!
After attaching oil pressure gauge, check that no fluid leakage exists.

4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D” or “R” range.
CAUTION!
• Do not continue running engine at stall speed longer than 5 seconds.
• After performing line pressure test, be sure to leave engine running at idle for longer than one minute before performing another line pressure test.

Automatic transaxle line pressure
Condition Possible cause Correction / Reference Item
“N”
→ “D” time lag
exceeds specification Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Clogged oil strainer Replace.
Faulty oil pump Inspect. If NG, replace.
Faulty forward clutch Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Leakage from “D” range fluid pressure
circuit Replace valve body assembly.
“N”
→ “R” time lag
exceeds specification Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Clogged oil strainer Replace.
Faulty oil pump Inspect. If NG, replace.
Faulty reverse clutch Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
“D” range
“R” range
At idle speed 3.8 – 4.2 kg/cm2, 54 – 60psi 5.9 – 6.9 kg/cm2, 84 – 98 psi
At stall speed 12.1 – 13.4 kg/cm2, 172 – 191 psi 16.8 – 19.5 kg/cm2, 239 – 277 psi

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-89
A/T Fluid Level CheckS7RS0B5106002
CAUTION!
Do not use any fluid other than the specified
ATF. Use of any fluid other than the specified
ATF may cause juddering or some other
faulty condition to occur.

Level Check at Normal Operating (Hot) Temperature
– Hot Check1) Drive vehicle so that A/T fluid temperature reach the
normal operating temperature (70 – 80 °C (158 –
176 °F)).
2) Stop vehicle with engine running and place it level.
3) With select lever at “P” range, apply parking brake and place chocks against wheels.
4) Keep engine idling and shift selector slowly to “L” and back to “P” position.
5) With engine idling, pull out fluid level gauge, wipe it off with a clean cloth and put it back into place.
6) Pull out fluid level gauge (1) again and check fluid level indicated on it. The lo west fluid level should be
between FULL HOT (2) and LOW HOT (3). If it is
below LOW HOT, add SUZUKI ATF 3317 or Mobil
ATF 3309 up to FULL HOT.
Automatic transaxle fluid
SUZUKI ATF 3317 or Mobil ATF 3309
NOTE
• Do not race engine while checking fluid level, even after the engine start.
• Do not overfill. Overfilling can cause foaming and loss of fluid through breather.
Then slippage and transaxle failure can
result.
• Bringing the level from LOW HOT to FULL HOT requires 0.4 liters (0.85 / 0.70 US/Imp.
pt).
• If vehicle was driven under high load such as pulling a trailer, fluid level should be
checked about half an hour after it is
stopped.

Level Check at Room (Cold) Temperature – Cold
Check
Fluid level can be checked temporarily at room (cold)
temperature which correspond to 20 – 30 °C (68 – 86
° F). This level check is considered to be preparation
before performing level check under normal operating
(hot) temperature. Checking procedure itself is the same
as that described in “Level Check at Normal Operating
(Hot) Temperature – Hot Check: ”. If fluid level is
between “FULL COLD” (4) and “LOW COLD” (5),
proceed to test drive. And when fluid temperature has
reached normal operating temp erature, check fluid level
again and adjust it as necessary.
CAUTION!
Fluid level check at room (cold) temperature
is recommended only for preparation of level
check under normal (hot) operating
condition.
Failure to perform fluid level check under
normal (hot) operating temperature may
result in damage to transaxle.

4. “FULL COLD” mark 5. “LOW COLD” mark
1. Fluid level gauge 2. “FULL HOT” mark 3. “LOW HOT” mark
I3RM0B510032-01
I3RM0B510032-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-1
Transmission / Transaxle
Manual Transmission/Transaxle
General Description
Manual Transaxle Construction and ServicingS7RS0B5201001
The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs and three shafts
(input shaft, countershaft and reverse gear shaft). All forward gears are in constant mesh, and reverse uses a sliding
idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is don e on input shaft and engaged with input shaft 3rd gear or
4th gear. The 5th speed synchronizer sleev e & hub on input shaft is engaged with input shaft fifth gear mounted on the
input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used.
The device utilizes the 5th synchromesh, which is the lever synchro type, to appl y the brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of
shifting to 2nd gear.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
For servicing, it is ne cessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tight ened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.
Further, care must be taken to adjust preload of count ershaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

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.

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-3
Clutch Release Margin “C”1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) dep ressed, slightly push the
shift lever to re verse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by
“C” in figure.
Clutch release margin
“C”: 25 – 55 mm (0.98 – 2.17 in.)
6) If “C” is not within specificat ion, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”. Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS7RS0B5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to reservoir cap.
Air Bleeding of Clutch SystemS7RS0B5306003
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding
operation.
Brake Fluid
Refer to reservoir cap
2) Remove bleeder plug cap from clutch operating cylinder (3). Attach a vinyl tube (1) to bleeder plug
(4), and insert the other end into container (2).
2
1
“A”
3
2
1
3
“B”
“C”
4
5
I4RS0B530001-01
I4RS0A530023-01
3 4 1
2
3
I4RS0A530003-01

Downloaded from www.Manualslib.com manuals search engine 5C-8 Clutch:
Clutch Cover, Clutch Disc and Flywheel ComponentsS7RS0B5306013
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S7RS0B5306014
Removal1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with specia l tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811
8. Clutch pedal : Apply grease 99000-25011 to outside surface of pin.
(a)
(b)
(b)
A
A
A
12
115
6
A3
A4
710
2
98
1
I4RS0A530013-02
1. Flywheel 9. Clutch disc
2. Flywheel bolt 10. Clutch cover bolt
3. Clutch release shaft seal : Apply grease 99000-25011 to seal lip. 11. Release arm
4. Clutch release shaft No.2 bush : Apply grease 99000-25011 to bush inside. 12. Release arm bolt
5. Clutch release shaft : Apply grease 99000-25011 to the end of release shaft arm. :70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
6. Clutch release shaft No.1 bush : Apply grease 99000-25011 to bush inside. :23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
7. Release bearing : Apply grease 99000-25011 to joint of bearing and release shaft and also bearing inside. Do not reuse.
8. Clutch cover
I4RS0A530014-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-9
3) Pull out input shaft bearing (1) from flywheel (2), use the following special tool if necessary.
Special tool
(A): 09921–26020
(B): 09930–30104
4) Remove flywheel (1) from crank shaft using special tool.
Special tool
(A): 09924–17811 Installation
CAUTION!
Do not reuse flywheel bolts. Otherwise, bolts
may loosen. Be sure to use new bolts with
pre-coated adhesive.

NOTE
Before assembling, make
sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (2) to crankshaft and tighten new bolts (1) to specification.
Special tool
(A): 09924–17811
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)
2) Using special tool, install input shaft bearing to flywheel (1).
Special tool
(B): 09925–98210
I2RH01530023-01
I4RS0A530015-02
I2RH01530024-01
I4RS0A530016-01