2006 SUZUKI SWIFT Information

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-15
Diagnostic Information and Procedures
A/T System CheckS7RS0B5104001
Refer to the following items for the details of each step.Step Action Yes No 1 ) Customer complaint analysis
1) Perform customer complaint analysis.
Was customer complaint analysis performed? Go to Step 2. Perform customer
complaint analysis.
2 ) DTC / freeze frame data check, record and clearance
1) Check for DTC.
Is there any DTC(s)? Print DTC or write them
down and clear them by
referring to “DTC
Clearance”. Go to Step
3.Go to Step 4.
3 ) Visual inspection
1) Perform visual inspection.
Is there any faulty condition? Repair or replace
malfunction part. Go to
St ep 11 .
Go to Step 5.
4 ) Visual inspection
1) Perform visual inspection.
Is there any faulty condition? Repair or replace
malfunction part. Go to
St ep 11 .
Go to Step 8.
5 ) Trouble symptom confirmation
1) Confirm trouble symptom.
Is trouble symptom identified? Go to Step 6.
Go to Step 7.
6 ) Rechecking and record of DTC / freeze frame data
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 8.
7 ) Rechecking and record of DTC / freeze frame data
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 10.
8 ) A/T basic check and A/T symptom diagnosis
1) Check and repair according to “A/T Basic Check” and “A/
T Symptom Diagnosis”.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
9 ) Troubleshooting for DTC
1) Check and repair according to applicable DTC flow.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
10 ) Check for intermittent problems
1) Check for interm ittent problems.
Is there any faulty condition? Repair or replace
malfunction part(s). Go
to Step 11.
Go to Step 11.
11 ) Final confirmation test
1) Clear DTC if any.
2) Perform final confirmation test.
Is there any problem symptom, DTC or abnormal condition? Go to Step 6.
End.

Downloaded from www.Manualslib.com manuals search engine 5A-16 Automatic Transmission/Transaxle:
Step 1. Customer Complaint Analysis
Record details of the problem such as failure, complaint and how it occurred as described by the customer.
For this purpose, use of such an inspec tion form will facilitate collecting information to the point required for proper
analysis and diagnosis. Customer problem inspection form (Example)
NOTE
The form is a standard sample. It should be modified according to conditions characteristic of each
market.

I6RS0C510015-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-17
Step 2. DTC / Freeze Frame Data Check, Record and Clearance
First, referring to “DTC Check”, check DTC and pending DTC. If DTC exists, print or write down DTC and freeze frame
data and then clear malfunction DTC(s) by referring to “DTC Clearance”. Malfunction DTC indicates malfunction in the
system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and
normal condition has been restored. In order to know that, check symptom in question according to Step 5 and then
recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or fa ilure to clear the DTC in this step may result in an faulty
diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unnecessary.
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 engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained in “Step 1. Customer Complaint Analysis: ” and “Step 2. DTC
/ Freeze Frame Data Check, Record and Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and Freeze Frame Data
Refer to “DTC Check” for checking procedure.
Step 8. A/T Basic Check and A/T Symptom Diagnosis
Perform basic check of A/T according to “A/T Basic Check” first. When the end of the flow has been reached, check
the parts of the system suspected as a possible cause referring to “A/T Symptom Diagnosis” and based on symptoms
appearing on the vehicle (symptoms obtained through step s of customer complaint analysis, trouble symptom
confirmation and/or A/T basic check) and re pair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to “a pplicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector, actuator, TCM or other part and repair or replace faulty parts.
Step 10. Check for Intermittent Problem
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 vehicl e is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the DTC once and check to ensure that no malfunction DTC is
indicated.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-167
Specifications
Tightening Torque SpecificationsS7RS0B5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
A/T fluid drain plug 171.7 12.5 ) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor bolt 131.3 9.5 ) / )
Input shaft speed sensor bolt 5.5 0.55 4.0)
Valve body harness connector bolt 7.00.7 5.0 )
Shift solenoid bolt 111.1 8.0 )
Oil strainer bolt 101.0 7.5 ) / )
Oil pan bolt 7.00.7 5.0 ) / )
Transaxle and engine fastening bolt and nut 85 8.5 61.5)
Drive plate to torque converter bolt 252.5 18.0 )
Transaxle stiffener bolt 555.5 40)
Starter motor bolt and nut 505.0 36.5 )
Oil pump subassembly bolt 101.0 7.5 )
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 111.1 8.0 )
Final gear bolt 787.8 56.5 )
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 292.9 21) / ) / )
Manual detent spring bolt 101.0 7.5 )
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 252.5 18.0 )
Fluid reservoir LH plate bolt 101.0 7.5 )
Oil pump assembly bolt 252.5 18.0 )
Transaxle case plug 7.5 0.75 5.5)
Valve body harness connector bolt 5.5 0.55 4.0)
Valve body bolt 111.1 8.0 )
Fluid outlet union 252.5 18.0 )
Fluid cooler pipe union bolt 222.2 16.0 )
Fluid cooler pipe bracket bolt 101.0 7.5 )
Fluid filler tube bolt 101.0 7.5 )
Input shaft speed sensor bolt 111.1 8.0 )
Harness bracket bolt 232.3 17.0 )
Select cable clamp bolt 101.0 7.5 )
Transmission range sensor lock nut 70.7 5.0 )
Manual select lever nut 131.3 9.5 )
Engine mounting LH bracket bolt 555.5 40.0
)

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 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 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-13
Clutch Release System InspectionS7RS0B5306017
Clutch Release Bearing
Check clutch release bearing for smooth rotation. If
abnormality is found, replace it.
CAUTION!
Do not wash release bearing. Washing may
cause grease leakage and consequential
bearing damage.

Clutch Release Shaft
Check clutch release shaft and its pin for deflection or
damage.
If abnormality is found, replace it.
Specifications
Tightening Torque SpecificationsS7RS0B5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I3RM0A530020-01
I3RM0A530021-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
CPP switch lock nut 7.5 0.75 5.5 )
Clutch operating cylinder bolt 23 2.3 17.0 )
Flywheel bolt 70 7.0 51.0 )
Clutch cover bolt 23 2.3 17.0 )
Release lever bolt 23 2.3 17.0 )