2006 SUZUKI SWIFT ect

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-127
Direct Clutch Assembly InspectionS7RS0B5106040
Clutch Discs, Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated, discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Direct Clutch Return Spring Subassembly
Measure free length of direct clutch return spring.
Direct clutch return spring free length
“a”: 36.04 mm (1.419 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Direct Clutch Piston
Shake direct clutch piston lightly and check that check
ball (1) is not stuck.
Blow in low pressure air (Max. 100 kPa, 1 kg/cm
2, 15 psi)
to check ball to check that there is no leakage.
I2RH0B510172-01
I2RH0B510173-01
I2RH0B510174-01

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-132 Automatic Transmission/Transaxle:
• Measure forward clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
forward clutch retaining plate with proper thickness
from among the following table and replace it.
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.)
Available forward clutch retaining plate thickness
• Install reverse clutch cushion plate (1) in correct direction as shown in figure.
• Apply A/T fluid to reverse clutch cushion plate (1),
reverse clutch separator plate (2), discs (3) and
retaining plate (4).
• Install reverse clutch cushio n plate (1), reverse clutch
separator plate (2), discs (3), retaining plate (4) and
then snap ring (5) to inte rmediate shaft subassembly. • Install reverse clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
• Measure reverse clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
reverse clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
Available reverse clutch retaining plate thickness
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.1 mm (0.122 in.) 5
3.2 mm (0.126 in.) 2
3.3 mm (0.130 in.) 6
3.4 mm (0.134 in.) 3
3.5 mm (0.138 in.) 7
3.6 mm (0.142 in.) 4
1. Oil hole
I2RH0B510177-02
I3RM0B510062-01
[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
3.6 mm (0.142 in.) 4
I2RH0B510190-01
I2RH0B510191-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-133
Forward and Reverse Clutch Assembly
Inspection
S7RS0B5106044
Clutch, Discs, Separator Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Forward Clutch Return Spring Subassembly
Measure free length of fo rward clutch return spring.
Forward clutch return spring free length
24.04 mm (0.946 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Forward Clutch Piston Lip and Forward Clutch
Balancer Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
Forward Clutch Drum Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
I2RH0B510192-01
I2RH0B510193-01
I2RH0B510194-01
I2RH0B510195-01

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

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-143
2) As shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case.
3) Tighten final gear bolts (1) to specified torque.
NOTE
To avoid rust, apply A/T fluid to final driven
gear after installation.

Tightening torque
Final gear bolt (a): 78 N·m (7.8 kgf-m, 56.5 lb-ft)
4) After applying A/T fluid to output shaft speed sensor drive gear (1), install output shaft speed sensor drive
gear.
5) Install new differential side RH bearing (1) by using special tool and hydraulic press.
NOTE
Replace differential side RH bearing together
with bearing cup as a set.

Special tool
(A): 09913–70123 6) Install new differential side LH bearing (1) by using
special tool and hydraulic press.
NOTE
Replace differential side LH bearing together
with bearing cup as a set.

Special tool
(A): 09913–70123
Differential Assembly InspectionS7RS0B5106056
1) Hold differential case subassembly with soft jawed
vice and set special tools as shown.
Special tool
(A): 09900–20607
(B): 09900–20701
2) Measure differential gear thrust play.
Differential gear thrust play
Standard: 0.05 – 0.20 mm (0.002 – 0.008 in.)
3) If thrust play is out of specification, replace differential case subassembly.
2. Final driven gear
I2RH0B510230-01
I2RH0B510231-01
I2RH0B510232-01
I2RH0B510233-01
I2RH0B510234-01
I2RH0B510235-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

I2RH0B510252-01
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01