2006 SUZUKI SWIFT transmission shaft

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-145
Reassembly1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque
converter housing.
Tightening torque
Torque converter housing plug (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
2) Using special tools, assemble differential side RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
3) Using special tool, install countershaft RH bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
4) Using special tools, install new differential side oil seal to torque converter housing.
Special tool
(A): 09924–74510
(B): 09944–88220 Differential side oil seal installing depth
“a”: 2.6 – 3.6 mm (0.10 – 0.14 in.)
5) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
6) Install lubrication LH tube (1) and RH tube (2).
7) Install fluid reservoir RH plate (1) and lubrication tube clamp (2).
Tightening torque
Lubrication tube clamp bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
Fluid reservoir RH plate bolt (b): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
I2RH0B510242-01
(A)
(B)
I3RM0B510063-01
(B) (A)
I3RM0B510064-01
I2RH0B510245-02
I2RH0B510237-01
I2RH0B510246-01

Downloaded from www.Manualslib.com manuals search engine 5A-146 Automatic Transmission/Transaxle:
Transaxle Case Disassembly and ReassemblyS7RS0B5106058
Disassembly1) Remove differential side oil seal (1).
2) Remove countershaft LH bearing cup and shim with special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
3) Remove differential side LH bearing cup and shim with special tools.
Special tool
(A): 09944–96011
(B): 09942–15511 Reassembly
1) Using special tools, assemb le shim and differential
side LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
2) Using special tools, assemble shim and countershaft LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
I2RH0B510247-01
I2RH0B510248-01
I2RH0B510249-01
(B)
(A)
I3RM0B510065-01
(B) (A)
I3RM0B510066-01

Downloaded from www.Manualslib.com manuals search engine 5A-148 Automatic Transmission/Transaxle:
One-way clutch No.1 assembly1) Install one-way clutch No.1 assembly (2) to rear planetary sun gear subassembly (1).
2) Securing rear planetary sun gear subassembly, ensure that one-way clutch No.1 assembly rotates
only in one direction.
If the one-way clutch rotates in both directions or it
does not rotate in either direction, replace it with new
one.
Adjustment
Differential side bearing preload 1) After applying A/T fluid to differential assembly, fit it to transaxle case.
2) Install torque converter housing to transaxle case, then tighten bolts (1) to specified torque.
Tightening torque
Torque converter housing bolt (a): 29 N·m (2.9
kgf-m, 21 lb-ft) 3) Measure bearing preload (a) by using a special tool.
Special tool
(A): 09928–06050
Differential side bearing preload (a) measured as
starting torque
In the case of new bearing: 0.78 – 1.37 N ⋅m (7.9 –
13.9 kg-cm, 0.58 – 1.01 lb-ft)
In the case of reused bearing: 0.39 – 0.69 N ⋅m
(3.9 – 6.9 kg-cm, 0.29 – 0.51 lb-ft)
4) If bearing preload is out of specification, select shim with suitable thickness from among the list below
and replace it. Then adjust differential side bearing
preload within specification.
Available shim thickness
NOTE
Record measured differential side bearing,
because it is necessary to adjust
countershaft bearing preload.

5) Remove differential assembly.
I2RH0B510254-01
I2RH0B510255-01
Thickness Identification mark
1.80 mm (0.070 in.) A
1.85 mm (0.072 in.) B
1.90 mm (0.074 in.) C
1.95 mm (0.076 in.) D
2.00 mm (0.078 in.) E
2.05 mm (0.080 in.) F
2.08 mm (0.081 in.) G
2.11 mm (0.083 in.) H
2.14 mm (0.084 in.) J
2.17 mm (0.085 in.) K
2.20 mm (0.087 in.) L
2.23 mm (0.088 in.) M
2.26 mm (0.089 in.) N
2.29 mm (0.090 in.) P
2.32 mm (0.091 in.) Q
2.35 mm (0.092 in.) R
2.40 mm (0.094 in.) S
2.45 mm (0.096 in.) T
2.50 mm (0.098 in.) U
2.55 mm (0.100 in.) V
2.60 mm (0.102 in.) W
2.65 mm (0.104 in.) X
2.70 mm (0.106 in.) Y
I2RH0B510256-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-149
Countershaft bearing preload1) After applying A/T fluid to countershaft assembly (1) and differential assembly (2), fit them.
2) Install torque converter housing to transaxle case, then tighten bolts to specified torque.
Tightening torque
Torque converter housing bolt: 29 N·m (2.9 kgf-
m, 21 lb-ft)
3) Measure bearing preload (b) by using special tool. Special tool
(A): 09928–06050
Countershaft bearing preload (b) measured as
starting torque
In the case of new bearing: 0.33 – 0.96 N⋅ m (3.3 –
9.8 kg-cm, 0.24 – 0.69 lb-ft)
In the case of reused bearing: 0.17 – 0.38 N ⋅m
(1.7 – 3.8 kg-cm, 0.12 – 0.28 lb-ft) 4) If bearing preload is out of specification, select shim
with suitable thickness from among the list below
and replace it. Then adjust countershaft bearing
preload within specification.
Available shim thickness
5) Remove differential assembly and countershaft assembly.
Countershaft bearing
preload =(b) – Differential side bearing
preload (a)
I2RH0B510257-01
I3RM0B510067-01
Thickness Identification mark
1.70 (0.066 in.) 1
1.75 (0.068 in.) 2
1.80 (0.070 in.) 3
1.85 (0.072 in.) 4
1.90 (0.074 in.) 5
1.93 (0.075 in.) 6
1.96 (0.077 in.) 7
1.99 (0.078 in.) A
2.02 (0.079 in.) B
2.05 (0.080 in.) C
2.08 (0.081 in.) D
2.11 (0.083 in.) E
2.14 (0.084 in.) F
2.17 (0.085 in.) G
2.20 (0.086 in.) H
2.25 (0.088 in.) K
2.30 (0.090 in.) L
2.35 (0.092 in.) M
2.40 (0.094 in.) N
2.45 (0.096 in.) P
2.50 (0.098 in.) Q
2.55 (0.100 in.) R
2.60 (0.102 in.) S
2.65 (0.104 in.) U
2.70 (0.106 in.) W

Downloaded from www.Manualslib.com manuals search engine 5A-150 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS7RS0B5106060
CAUTION!
• Automatic transaxle consists of highly precise parts. As even flaw in small part
may cause oil leakage or decrease in
function, check each part carefully before
installation.
• Clean all parts with compressed air. Never use wiping cloths or rags.
• Before assembling new clutch or brake discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before
assembly.
• Use Suzuki Super Grease “C” to retain parts in place.
• Be sure to install thrust bearings and races in correct direction and position.
• Make sure that snap ring ends are not aligned with one of cut outs and are
installed in groove correctly.
• Do not use adhesive cements on gaskets and similar parts.
• Be sure to torque each bolt and nut to specification.

1) Install new manual shift sh aft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.5 – 1.5 mm (0.02 – 0.06 in.) 2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl ro d (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using spring pin remover with 3.5 mm (0.14 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
I2RH0B510258-01
I2RH0B510259-01
I2RH0B510260-01
I2RH0B510261-01

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 Automatic Transmission/Transaxle: 5A-159
47) Install transaxle rear cover assembly on transaxle case.
48) Install hook (2) to location shown in figure.
49) Tighten rear cover bolts (1).
Tightening torque
Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
50) Install fluid reservoir LH plate (1). Tightening torque
Fluid reservoir LH plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
51) After applying A/T fluid to new governor apply No.2 gasket (1), install it to transaxle case. 52) After applying A/T fluid to differential assembly (1)
and countershaft assembly (2), install them to
transaxle case.
53) After applying A/T fluid to di rect clutch hub (1), install
it to planetary gear assembly.
54) After applying A/T fluid to input shaft rear thrust
bearing (1) and thrust bearing race (2), install them
into direct clutch hub (3).
I3RM0B510068-01
I2RH0B510303-01
I2RH0B510304-01
1
2
I4RS0A510036-01
I2RH0B510306-01
I2RH0B510307-01

Downloaded from www.Manualslib.com manuals search engine 5A-160 Automatic Transmission/Transaxle:
55) After applying A/T fluid to input shaft front thrust bearing (1), install it to direct clutch assembly (2).
56) Apply A/T fluid to direct clutch assembly (1). Install direct clutch a ssembly while rotating
clockwise and counterclockwise frequently to fit
clutch discs to mating hub.
NOTE
Before installation, align teeth of direct clutch
discs to facilitate installation.

57) Check for correct installation of direct clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
direct clutch assembly, direct clutch hub and reinstall
them properly.
Distance between direct clutch assembly and
mating surface of transaxle case
“a”: 10.4 – 11.4 mm (0.409 – 0.449 in.) 58) Install oil pump assembly
(1) to transaxle case.
Tightening torque
Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
59) Make sure that input shaft (1) turns smoothly.
I2RH0B510308-01
I2RH0B510309-01
“a”
“a”
1
2
I2RH0B510310-01
I2RH0B510311-01
I2RH0B510312-01