2007 SUZUKI SWIFT pin

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-17
5) Remove gear shift locating bolts (1) with washers,
then take out locating springs and steel balls.
6) Remove back up light switch (2).
7) Remove reverse shaft bolt (2) with washer.
8) Remove case bolts (1) from outside and another bolts from clutch housing side.
9) Tapping left case flanges with plastic hammer, remove left case (3).
10) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3).
11) Remove reverse gear shift lever bolts (4) and reverse gear shift lever (5).
12) Pull out 5th & reverse gear shift guide shaft (6) together with 5th & reverse gear shift shaft (7). 13) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, then take out
input shaft assembly (1), countershaft assembly (2),
high speed gear shift shaft (3) and low speed gear
shift shaft (4) all at once.
14) Remove countershaft left bearing outer race from left case (1) using special tool.
Special tool
(A): 09913–70123
15) Remove side bearing retainer bolts.
16) Turn side bearing retainer (1) counterclockwise until it stops, and remove side bearing retainer using 2 flat
end rods (2) or the like.
17) Remove O-ring from side bearing retainer.
I2RH01520032-01
I4RS0A520032-01
I4RS0A520033-01
I2RH01520035-01
(A)
1
I4RH01520021-01
1
2
2
I4RS0A520034-01

Downloaded from www.Manualslib.com manuals search engine 5B-18 Manual Transmission/Transaxle:
18) Remove differential bearing shim.
19) Remove differential side bearing outer race from left case (1) using special tools.
Special tool
(A): 09924–74510
(B): 09926–27610
20) Remove differential gear assembly (1) from right case (2).
Reassembly 1) Install differential assembly (1) into right case (2). 2) Join input shaft assembly (5), countershaft assembly
(4), low speed gear shift shaft (2) and high speed
gear shift shaft (3) assemblies all together, then
install them into right case (1).
CAUTION!
Take care not to damage oil seal lip by input
shaft, or oil leakage may take place.

NOTE
• Input shaft right bearing on shaft can be
installed into right case tapping shaft with
plastic hammer.
• Check to make sure that countershaft is engaged with final g ear while installing.

3) Install 5th & reverse gear shift shaft (1) with 5th &
reverse gear shift guide shaft (2) into right case (5).
Reverse gear shift arm (4) has to be joined with
reverse gear shift lever (3) at the same time.
(A)
(B)
1
I4RS0A520035-01
I6RS0C520006-02
I6RS0C520006-02
I2RH01520080-01
I2RH01520081-01

Downloaded from www.Manualslib.com manuals search engine 5B-32 Manual Transmission/Transaxle:
5th and Reverse Gear Shift Shafts Disassembly
and Assembly
S7RS0B5206023
Disassembly
Disassemble component parts using special tool and
hammer.
Special tool
(A): 09922–85811
Assembly
Replace or correct parts as required and assemble
shafts making sure that component parts are in proper
order as shown.
NOTE
• Distinguish reverse gear shift arm spring (Blue) (2) from low speed locating spring
(Yellow).
• Install 2 steel balls (3) in reverse gear shift arm (1) without fail.
• Drive in spring pin for reverse gear shift arm facing slit A toward 5th gear side.

Gear Shift Shaft and Fork InspectionS7RS0B5206024
Using feeler gauge, check clearance between fork (1)
and sleeve (2) and replace those parts if it exceeds limit.
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Service limit “a”: 1.0 mm (0.039 in.)
Insert each gear shift shaft into case and check that it
moves smoothly. If it doesn’t, correct using oilstone,
reamer or the like.
A: Face pin slit toward 5th gear side
4. Spring pin
5. 5th & reverse gear shift shaft
6. 5th & reverse gear shift yoke
7. 5th & reverse gear shift guide shaft
8. 5th gear side
I3RM0A520053-01
I2RH01520068-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-33
Differential ComponentsS7RS0B5206025
Differential Disassembly and AssemblyS7RS0B5206026
Disassembly1) Using special tools, remove right bearing (1).
Special tool
(A): 09913–60910
(B): 09925–88210 2) Remove left bearing in the same manner at Step 1).
3) Support differential case with soft jawed vise and
remove final gear bolts then take out final gear.
4) Using special tool and hammer, drive out differential pinion shaft pin and then disassemble component
parts.
Special tool
(C): 09922–85811
1. Differential pinion washer 8. Final gear
2. Differential side pinion gear 9. Final gear bolt
3. Differential side gear 10. Differential pinion shaft
4. Side gear washer : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
5. Differential side bearing : Do not reuse.
6. Differential pinion shaft pin : Apply transaxle oil.
7. Differential case
I6RS0C520007-01
1(B)
(A)
I5JB0A321013-02
1. Differential case
2. Differential gear
3. Differential pinion shaft
IYSY01521077-01

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly. Make sure that all parts are clean.
1) Assemble differential gear and measure thrust play
of differential gear as follows.
Special tool
(A): 09900–20607
(B): 09900–20701
Differential gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
1. Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top
surface of gear (2).
2. Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.
Right side
1. Using similar procedure to the left side, set dial gauge tip to gear (2) shoulder.
2. Move gear up and down by hand and read dial gauge.
2) If thrust play is out of sp ecification, select suitable
thrust washer from among the following available
size, install it and check again that specified gear
play is obtained.
Available thrust washer thickness
3) Drive in new differential pinion shaft pin (2) till the depth from differential case (3) surface is about 1
mm (0.04 in.).
4) Press-fit left bearing (2) using special tool and copper hammer.
Special tool
(A): 09913–76010
5) Support differential assembly (1) as illustrated so as to left bearing is floating , and then press-fit right
bearing (3) using special tools.
Special tool
(A): 09913–76010
(B): 09951–16060
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.90 mm (0.035 in.) 1.10 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.00 mm (0.039 in.)
[A]: Left side
[B]: Right side
I3RH0A520083-01
1
(A)
3
2 (B)
I6RS0C520008-01

Downloaded from www.Manualslib.com manuals search engine 5B-36 Manual Transmission/Transaxle:
Special Tools and Equipment
Recommended Service MaterialS7RS0B5208001
NOTE
Required service material is also described in the following.
“Gear Shift Control Leve r and Cable Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Input Shaft and Countershaft Components”
“Gear Shift Shaft Components”
“Differential Components”

Special ToolS7RS0B5208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / ) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / ) / ) / ) /
)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 ) / ) / ) / ) / )
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09913–50121 09913–60910
Oil seal remover Bearing and gear puller (40-
60mm)
))
09913–70123 09913–76010
Bearing installing t ool Bearing installer
) / ) / )) / )
09913–80113 09913–84510
Bearing installer Bearing installer
)) / ) / )
09913–85210 09922–85811
Bearing installer Spring pin remover (4.5 mm)
) / )) / ) / )

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-37
09923–7451009923–78210
Bearing puller (20-35 mm) Bearing installer
)) / ) / ) / )
09924–07710 09924–07730
Synchronizer hub installer Bearing installer
))
09924–74510 09924–84510–004
Bearing and oil seal handle Bearing installer attachment
))
09925–15410 09925–78210
Oil seal installer Spring pin remover (6 mm)
))
09925–88210 09925–98210
Bearing puller attachment Input shaft bearing installer
))
09926–27610 09927–76060
Oil seal installer Gear holder
) / )) / )
09930–30104 09940–51710
Sliding shaft Bearing installer
) / ))
09941–64511 09951–16060
Bearing and oil seal remover
(30 mm Min.) Control arm bush remover
))

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.