2006 SUZUKI SWIFT 1.1

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-157
38) After applying A/T fluid to intermediate shaft thrust bearing rear race (3), thrust bearing (2) and front
race (1), install them to forward and reverse clutch
assembly (4).
Bearing race dimension
39) Apply A/T fluid to forward and reverse clutch assembly (1).
Install forward and revers e clutch assembly while
rotating clockwise and co unterclockwise frequently
to fit clutch discs to mating hubs.
NOTE
Before installation, align teeth of forward and
reverse clutch discs to facilitate installation.

40) Check for correct installation of forward and reverse clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
forward and reverse clutch assembly, forward clutch
hub, rear planetary sun gear subassembly and one-
way clutch No.1 assemb ly, and reinstall them
properly.
Distance between forward and reverse clutch
assembly and mating surface of transaxle case
“a”: Less than 29.4 mm (1.157 in.)
41) After applying A/T fluid to O/D and 2nd coast brake retaining plate (4), separator plate (3), discs (2) and
rear plate (1), install th em to transaxle case (5).
Front race Rear race
Outside
diameter 30.6 mm (1.20 in.) 28.2 mm (1.11 in.)
Thickness 2.0 mm (0.08 in.) 2.0 mm (0.08 in.)
I2RH0B510294-01
I2RH0B510295-01
“a”
“a”
1 2
I2RH0B510296-01
I2RH0B510297-01

Downloaded from www.Manualslib.com manuals search engine 5A-162 Automatic Transmission/Transaxle:
66) After applying A/T fluid to new O-ring, fit it to transaxle case plug (1). Then install the transaxle
case plug to transaxle case (2).
Tightening torque
Transaxle case plug (a): 7.5 N·m (0.75 kgf-m, 5.5
lb-ft)
67) Install new O-rings to each accumulator piston and apply A/T fluid to them.
Accumulator O-ri ng dimension
NOTE
Make sure that O-rings are not twisted or
caught when installing.

68) Install B1, C1, C2 accumulator pistons and springs.
Accumulator piston identification
Accumulator spring identification
69) After applying A/T fluid to cooler check valve (1) and
spring (2), install them to transaxle case (3).
O-ring name
Inside
diameter Section
diameter
Large B1 accumula tor O-ring (2)
Large C1 accumula tor O-ring (2)
Large C2 accumula tor O-ring (2)
– Above three O-rings are same. 29.4 mm
(1.16 in.) 2.6 mm
(0.10 in.)
Small B1 accumulator O-ring (4) 19.7 mm
(0.78 in.) 2.6 mm
(0.10 in.)
Small C1 accumulator O-ring (6)
Small C2 accumulator O-ring (6)
– Above two O-rings are same. 21.8 mm
(0.86 in.) 2.6 mm
(0.10 in.)
Piston name Identification as
embossed letters on piston
B1 accumulator piston (3) SB-1
C1 accumulator piston (5) S2C-1
C2 accumulator piston (8) S2C-2
Spring name Color of identification
paint
B1 accumulator No.2
spring (1) Pink
C1 accumulator No.2
spring (7) Light blue
C2 accumulator No.2
spring (9) Yellow
I2RH0B510317-01
I2RH0B510318-01
I2RH0B510319-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-163
70) After applying A/T fluid to new governor apply No.1 gasket (1), install it to transaxle case.
71) After applying A/T fluid to new O-ring, fit it to valve body harness connector (3), then install valve body
harness to transaxle case.
CAUTION!
When put valve body harness (1) into
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow entrance of case.
Careless sensor treatment might cause
sensor malfunction.

Tightening torque
Valve body harness connector bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft) 72) Install manual valve rod (1) to manual valve lever (3)
and then install valve body assembly (2) to transaxle
case.
73) Tighten valve body bolts to specified torque. Tightening torque
Valve body bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Valve body bolt length
I2RH0B510320-01
I2RH0B510321-01
Bolt Length “a” Pieces
A (1) 20 mm (0.79 in.) 6
B (2) 28 mm (1.10 in.) 5
C (3) 49 mm (1.93 in.) 1
D (4) 36 mm (1.42 in.) 1
E (5) 40 mm (1.58 in.) 1
I2RH0B510322-01
I2RH0B510323-01

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 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 5B-8 Manual Transmission/Transaxle:
Manual Transaxle Unit ComponentsS7RS0B5206008
13
6(a)
5
14(c)
114 7
(b)
12
7(b)
8
2
5 [A]
1
10
6
(a)
(a)
(b)3
9
9
(b)
(d)
I6RS0C520004-03
[A]: Forward
7. Engine left mounting bracket bolt and nuts 14. Clutch operating cylinder bolt
1. Engine 8. Clutch housing lower plate : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
2. Transaxle 9. Engine rear mounting bracket bolts : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
3. Engine rear mounting and bracket 10. Transaxle to engine nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Back up light switch connector 11. Ground cable : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
5. Clutch operating cylinder 12. Engine left mounting bracket
6. Transaxle to engine bolt 13. Gear shift & select control cables

Downloaded from www.Manualslib.com manuals search engine 5B-20 Manual Transmission/Transaxle:
9) Install side bearing retainer as follows.a) Install differential side bearing outer race to left case and then tap and accustom outer race
using special tool and plastic hammer.
CAUTION!
Do not drive in a race with hammer.
Driving it may cause to damage bearing.

Special tool
(A): 09926–27610
b) Select a shim of differential side bearing as follows.
i) Measure depth “a” from left case (1) face to side bearing outer race (2) using depth
gauge.
ii) Measure height “b” of side bearing retainer with depth gauge. iii) Calculate clearance a – b, and select
differential shim acco rding to the following
table.
Bearing shim specification
(A)
I4RH01520053-01
I4RS0A520037-01
“b”
I4RS0A520038-01
Clearance “a” – “b” Thickness of bearing
shim to be installed
0.636 – 0.665 mm
(0.0250 – 0.0261 in.) 0.75 mm (0.030 in.)
0.666 – 0.695 mm
(0.0262 – 0.0273 in.) 0.78 mm (0.031 in.)
0.696 – 0.725 mm
(0.0274 – 0.0285 in.) 0.81 mm (0.032 in.)
0.726 – 0.755 mm
(0.0286 – 0.0297 in.) 0.84 mm (0.033 in.)
0.756 – 0.785 mm
(0.0298 – 0.0309 in.) 0.87 mm (0.034 in.)
0.786 – 0.815 mm
(0.0310 – 0.0320 in.) 0.90 mm (0.035 in.)
0.816 – 0.845 mm
(0.0321 – 0.0332 in.) 0.93 mm (0.037 in.)
0.846 – 0.875 mm
(0.0333 – 0.0344 in.) 0.96 mm (0.038 in.)
0.876 – 0.905 mm
(0.0345 – 0.0356 in.) 0.99 mm (0.039 in.)
0.906 – 0.935 mm
(0.0357 – 0.0368 in.) 1.02 mm (0.040 in.)
0.936 – 0.965 mm
(0.0369 – 0.0379 in.) 1.05 mm (0.041 in.)
0.966 – 0.995 mm
(0.0380 – 0.0391 in.) 1.08 mm (0.043 in.)
0.996 – 1.025 mm
(0.0392 – 0.0403 in.) 1.11 mm (0.044 in.)
1.026 – 1.055 mm
(0.0404 – 0.0415 in.) 1.14 mm (0.045 in.)
1.056 – 1.085 mm
(0.0416 – 0.0427 in.) 1.17 mm (0.046 in.)
1.086 – 1.115 mm
(0.0428 – 0.0438 in.) 1.20 mm (0.047 in.)
1.116 – 1.145 mm
(0.0439 – 0.0450 in.) 1.23 mm (0.048 in.)
1.146 – 1.175 mm
(0.0451 – 0.0462 in.) 1.26 mm (0.050 in.)
1.176 – 1.205 mm
(0.0463 – 0.0474 in.) 1.29 mm (0.051 in.)
1.206 – 1.235 mm
(0.0475 – 0.0486 in.) 1.32 mm (0.052 in.)
1.236 – 1.265 mm
(0.0487 – 0.0498 in.) 1.35 mm (0.053 in.)
1.266 – 1.295 mm
(0.0499 – 0.0509 in.) 1.38 mm (0.054 in.)
1.296 – 1.325 mm
(0.0510 – 0.0521 in.) 1.41 mm (0.056 in.)

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