2007 SUZUKI SWIFT shift lever

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-13
Manual Transaxle Assembly ComponentsS7RS0B5206013
I6RS0C520005-01
1. Transaxle right case 24. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case : Apply sealant 99000-31260 to mating surface of left case and right
case. 25. 5th gear shift fork
3. Gear shift and select shaft assembly 26. Needle bearing
4. Transaxle left case plate 27. Input shaft 5th gear
5. Transaxle side cover : Apply sealant 99000-31260 to mating surface of side cover and left
case. 28. Reverse gear shift lever
6. Back up light switch 29. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring 30. Reverse gear shaft
8. Differential assembly 31. Washer
9. Oil level/filler plug : Apply sealant 99000-31260 to all around thread part of plug. 32. Reverse idler gear
10. Oil drain plug : Apply sealant 99000-31260 to all around thread part of plug. 33. Reverse shaft bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.

Downloaded from www.Manualslib.com manuals search engine 5B-14 Manual Transmission/Transaxle:
Fifth Gear Disassembly and AssemblyS7RS0B5206014
Disassembly1) Remove cover bolts and take off transaxle side cover (1).
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using snap ring pliers, remove circlip (1).
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchron izer levers, synchronizer
ring and input shaft 5th gear (5) all together. Use
gear puller for removal if spline fitting of hub is tight. 5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
11. Sensor cap 34. Washer
12. Oil gutter bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 35. Side bearing retainer
13. Left case plate bolts : Apply thread lock 99000-32110 to all around thread part of bolt. 36. O-ring
14. Sensor cap bolt 37. Oil seal
: Apply grease 99000-25011 to oil seal lip.
15. Side cover bolts 38. Outer race
16. Transaxle case bolts 39. Breather hose
17. 5th speed synchronizer ring 40. Side bearing retainer bolt
18. 5th speed synchronizer lever : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
19. 5th speed synchronizer sleeve & hub : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
20. Circlip :10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
21. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
22. Countershaft 5th gear : Do not reuse.
23. Countershaft nut : After tightening nut to specified torque, caulk nut securely. : Apply transaxle oil.
I4RS0A520027-01
342
1
5
I4RS0A520028-01
1(A)
2
I3RM0B521014-01
I4RS0A520041-01

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 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-35
6) Hold differential assembly with soft jawed vise (3),
install final gear (2) as shown in figure and then
tighten bolts (1) to specified torque.
CAUTION!
Use of any other bolts than specified ones is
prohibited.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS7RS0B5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Leve r and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A520043-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Transaxle oil drain plug 21 2.1 15.5 )
Transaxle oil level / filler plug 21 2.1 15.5 )
Back up light switch 23 2.3 17.0 )
Gear shift guide case bolt 23 2.3 17.0 )
Select lever bracket bolt 23 2.3 17.0 )
Gear shift interlock bolt 23 2.3 17.0 )
5th to reverse interlock guide bolt 23 2.3 17.0 )
Countershaft nut 100 10.0 72.5 )
Shift fork bolt 10 1.0 7.5 )
Side cover bolt 10 1.0 7.5 )
Reverse gear shift lever bolt 23 2.3 17.0 )
Reverse shaft bolt 23 2.3 17.0 )
Transaxle case bolt 23 2.3 17.0 )
Side bearing retainer bolt 23 2.3 17.0 )
Gear shift locating bolt 13 1.3 9.5 )
Left case plate bolt 23 2.3 17.0 )
Oil gutter bolt 10 1.0 7.5 )
Final gear bolt 90 9.0 65.0 )

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-3
Clutch Release Margin “C”1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) dep ressed, slightly push the
shift lever to re verse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by
“C” in figure.
Clutch release margin
“C”: 25 – 55 mm (0.98 – 2.17 in.)
6) If “C” is not within specificat ion, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”. Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS7RS0B5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to reservoir cap.
Air Bleeding of Clutch SystemS7RS0B5306003
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding
operation.
Brake Fluid
Refer to reservoir cap
2) Remove bleeder plug cap from clutch operating cylinder (3). Attach a vinyl tube (1) to bleeder plug
(4), and insert the other end into container (2).
2
1
“A”
3
2
1
3
“B”
“C”
4
5
I4RS0B530001-01
I4RS0A530023-01
3 4 1
2
3
I4RS0A530003-01

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-24
L: Floor harness
L: ACC socket wire
L: License plate wire
R: Fuel pump wireNo./Color Connective position No./Color Connective position
L01/BLU BCM L27/BLK Parking brake switch L02/N Main harness (To E44) L28/BLU ACC socket wire (To L44)
L03/YEL Main harness (To E45) L29/PNK A/B SDM
L04/YEL J/B L29/BRN (With
Side A/B,
Curtain A/B System) A/B SDM
L05/N J/B L30/YEL (IF
EQPD) Side air-bag inflator (Passenger side)
L06/N J/B L31/N Front door wire (Passenger side) (To J09)
L07/N Front door wire (Driver side) (To J01) L32/YEL Instrument panel harness (To G04)
L10/BLK Pretensioner (Driver side) L33/N Instrument panel harness (To G03)
L11/N (IF EQPD) Driver side-sensor L34/N Front door switch (Passenger side)
L12/N Front door switch (Driver side) L35/N Passenger side-sensor
L13/N Rear door wire (R) (To J16) L 36/BLK Pretensioner (Passenger side)
L14/N Wheel speed sensor (RR) L37/N Rear door wire (L) (To J21)
L15/GRY Fuel pump wire (To R01) L38/N Wheel speed sensor (RL)
L16/N Rear door switch (R) L39/N Antenna amplifier
L17/N High mounted stop light L40/N Rear door switch (L)
L18/BLK (IF EQPD) Side curtain air-bag (R) L41/BLK (IF
EQPD) Side curtain air-bag (L)
L19/GRY Luggage compartment light L42/N Rear end door wire (To O01) L20/N Rear combination light (R) L43/BLK Rear combination light (L)
L21/N License plate wire (To L22) L51/ GRY Instrument panel harness (To G43)
L23/N (A/T) A/T shift lever L59/GRY (IF
EQPD) Rear end antenna
L24/GRY J/C L65/BRN (IF
EQPD) Inside antenna
L25/YEL (IF EQPD) Side air-bag inflator (Driver side) L66/BRN (IF
EQPD) Luggage antenna
L26/N Seat belt switch L74/BLU J/C
No./Color Connective position No./Color Connective position
L44/BLU Floor harness (To L28) L46/BLK ACC socket
No./ColorConnective position No./Color Connective position
L22/N Floor harness (To L21) L48/N License plate light #2
L47/N License plate light #1
No./Color Connective position No./Color Connective position
R01/GRY Floor harness (To L15) R03/N (IF
EQPD) Sub fuel level sensor
R02/BLK Fuel pump and gauge