2006 SUZUKI SWIFT IGN

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-165
81) After applying A/T fluid to new O-ring, fit it to fluid filler tube. Then install fl uid filler tube to transaxle
case.
Tightening torque
Fluid filler tube bolt (d): 10 N·m (1.0 kgf-m, 7.5
lb-ft)
82) Apply A/T fluid to O-rings of each sensor and install input shaft speed sensor (1) and output shaft speed
sensor (2).
Tightening torque
Input shaft speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Output shaft speed sensor bolt (b): 13 N·m (1.3
kgf-m, 9.5 lb-ft)
83) Install harness bracket (3) and select cable clamp (4).
Tightening torque
Harness bracket bolt (c): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Select cable clamp bolt (d): 10 N·m (1.0 kgf-m,
7.5 lb-ft) 84) Install transmission range sensor to transaxle case,
tighten bolts temporarily at this step.
85) Install lock washer (1) and tighten lock nut (2) to specified torque.
Tightening torque
Transmission range sensor lock nut (a): 7 N·m (
0.7 kgf-m, 5.0 lb-ft)
86) Install manual select leve r (1) temporarily at this
step.
87) After shifting manual se lect lever counterclockwise
fully, select “N” range position by bringing it back 2
notches clockwise.
88) Remove manual select lever (1) at this step.
89) Loosen sensor bolts (4) and align needle direction shaped on lock washer (2) with “N” reference line (3)
on transmission range sensor by moving sensor in
rotative direction.
90) Tighten sensor bolts to specified torque.
Tightening torque
Transmission range sensor bolt (b): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
(c)
(d)
(b)
2
1,(a)
(b)
2
I3RM0B510070-01
I3RM0B510071-01
I3RM0B510072-01
I3RM0B510073-01
I3RM0B510074-01

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 5B-12 Manual Transmission/Transaxle:
4) Install washer and gear shift interlock bolt (2) to which sealant have been app lied and then tighten it
to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift interlock bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
5) Install washer and 5th to reverse interlock guide bolt (3) to which sealant have been applied and then
tighten it to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
5th to reverse interlock guide bolt (c): 23 N·m (
2.3 kgf-m, 17.0 lb-ft)
Gear Shift and Select Shaft Disassembly and
Assembly
S7RS0B5206012
1) Push pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and
specified spring pin removers as shown below.
Special tool
(A): 09922–85811 4.5 mm
(B): 09925–78210 6.0 mm
2) Inspect component parts for wear, distortion or
damage. If any detect is found, replace detective
part with new one.
NOTE
• Set new gear shift & select lever inner pin (8) and outer pin (9) facing each gap (“a”,
“b”) in the opposite direction as shown in
figure.
• When driving in pins, prevent shaft from being bent by supporting it with wood
block.
• Assemble 5th & reverse gear shift cam with its pit and pin aligned.
• Make sure to select an appropriate spring by identifying the painted colors to keep
gear shifting performance as designed.
– Low speed select spring – Light blue
– Reverse select spring – Yellow

“A” 1, (a), “B”
1, (a), “B” 2, (b), “B”
3, (c), “B”
I4RS0A520025-01
1. E-ring 10. Ball
2. Washer 11. Gear shift & select shaft
3. Reverse select spring 12. 5th & reverse gear shift cam
4. Gear shift interlock plate 13. 5th & reverse gear shift cam guide pin
5. Ball 14. Cam guide return spring
6. Gear shift interlock spring 15. 5th & reverse gear shift cam guide
7. Gear shift & select lever 16. Gear shift cam guide pin
8. Inner pin 17. Low speed select spring
9. Outer pin 18. Spring pin remover
I6RS0C520011-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-15
Assembly1) Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and
synchronizer ring (4) as follows.
a) Install hub (1) to 5th speed synchronizer sleeves (2) in specified direction as shown in figure.
b) Fit 5th speed synchronizer levers (1) to hub (2) as shown in figure.
NOTE
Align protrusion A of 5th speed synchronizer
levers (1) with groove of hub (2).

c) Install synchronizer ring (1) to hub (2) as shown in figure.
2) Install 5th gear (1) to countershaft facing machined boss A inward.
3) Install needle bearing to input shaft, apply oil then install input shaft 5th gear (1) and special tool to stop
shaft rotation.
Special tool
(A): 09927–76060
4) Tighten new countershaft nut (2) to specified torque, and caulk countershaft nut securely.
Tightening torque
Countershaft nut (a): 100 N·m (10.0 kgf-m, 72.5
lb-ft)
A: Chamfered side B: Long boss
I4RH01520054-01
1
2
B
A
I4RH01520048-01
1A
2
A
I4RH01520049-01
A: Machined boss (Inside)
B: No machining (Outside)
1
2
I4RH01520055-01
I2RH01520088-01
1
(A)
2, (a)
I3RM0B521016-01

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
5) Fit 5th gear shift fork (1) to synchronizer sleeve (2) and hub (3) assembly and install them into input
shaft and gear shift shaft aligning punch mark (4)
with matching mark (5) on input shaft.
6) Tighten shift fork bolt (2) to which thread lock cement
has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
7) Using snap ring pliers, inst all new circlip (1) to input
shaft (3) in specified direction as shown in figure. 8) Clean mating surface of both left case (2) and side
cover (1), apply sealant to side cover (1) as shown in
figure by such amount t hat its section is 1.5 mm
(0.059 in.) in diameter, mate it with left case and then
tighten bolts to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Manual Transaxle Assembly Disassembly and
Reassembly
S7RS0B5206015
Disassembly
1) Remove gear shift and select shaft assembly referring to “Gear Shift an d Select Shaft Assembly
Removal and Installation”.
2) Remove fifth gear referring to “Fifth Gear Disassembly and Assembly”.
3) Remove left case plate.
4) Remove snap ring (1) using snap ring pliers (2).
4. Polished surface
I4RS0A520029-01
2, (a), “A”
1 33
4
1
I4RS0A520030-01
2. Input shaft 3. Input shaft left bearing
I4RS0A520031-01
1
2
2
3
I6RS0C520012-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-19
4) Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) into case (4)
through idler gear and then align “A” in shaft with “B”
in case.
5) Fasten reverse gear shift lever bolts after applying thread lock cement.
: Thread lock cement 99000–32110 (Thread Lock
Cement Super 1322)
Tightening torque
Reverse gear shift lever bolt: 23 N·m (2.3 kgf-m,
17.0 lb-ft)
NOTE
• Make sure that washer (5) has been installed in shaft at above the gear.
• Check to confirm that reverse gear shift lever end has clearance “a” to idler gear
groove.

Distance between lever and idler gear shaft
“a”: 0.5 – 1.0 mm (0.02 – 0.04 in.) 6) Clean mating surfaces of both right and left cases,
apply sealant to right case (2) as shown in the figure
by such amount that its section is 1.5 mm (0.059 in.)
in diameter then mate it with left case (1).
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
7) Install reverse shaft bolt (4) to which thread lock cement has been applied, with aluminum washer
and tighten it to specified torque.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Reverse shaft bolt (c): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
8) Tighten case bolts (3) from outside tighten another case bolts from clutch housing side to specified
torque.
Tightening torque
Transaxle case bolt (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
I4RS0A520036-01
I3RM0A520043-01

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

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-29
5) Apply bearing puller (3) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (1)
with 1st gear using hydraulic press.
CAUTION!
To avoid gear tooth from being damaged,
support it at flat side of bearing puller.

6) Disassemble low speed synchronizer sleeve & hub assembly.
7) Take out 1st gear needle bearing from shaft.
8) Remove right bearing cone (2) using bearing puller (3), metal stick (1) and hydraulic press.
Reassembly 1) Clean all components thor oughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) To ensure lubrication of countershaft (1), air blow oil holes (2) and make sure that they are free from any
obstruction. 3) Fit low 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 low speed synchronizer keys and springs are the largest compared with
those of high speed and 5th speed ones.

Synchronizer key installation position
A = B
4) Install right bearing cone (1) to countershaft (2) using special tool and hammer.
Special tool
(A): 09923–78210
I2RH01520057-01
I2RH01520058-01
I2RH01520060-01
[A]: 1st gear side D: Short flange
C: Key way
I3RM0A520051-01
I2RH01520062-01