2008 SUZUKI SWIFT Hydraulic

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-151
6) Install parking lock pawl bracket (1) to transaxle
case.
Tightening torque
Parking lock pawl bracket bolt (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
7) After applying A/T fluid to new O-rings, install them to 1st and reverse brake piston (3).
8) Install 1st and reverse brake piston (1) to transaxle case (2).
NOTE
Be careful not to damage O-ring when
installing 1st and reverse brake piston.

9) Install 1st and reverse brake return spring subassembly (1) to transaxle case (2).
10) Apply A/T fluid to 1st and reverse brake discs (2), separator plates (3) and retaining plate (1), then
install them to transaxle case.
11) Compress 1st and reverse brake return spring using special tool and hydraulic press, then attach snap
ring.
CAUTION!
Do not damage 1st and reverse brake return
spring subassembly discs, plates and piston
by pressing in 1st and reverse brake return
spring subassembly passing through its
original installing position over 0.8 mm (0.031
in.).

Special tool
(A): 09926–97620
1. Inner O-ring 2. Outer O-ring
I2RH0B510262-01
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I2RH0B510264-01
I2RH0B510265-01
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Downloaded from www.Manualslib.com manuals search engine 5A-152 Automatic Transmission/Transaxle:
12) Install 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations
as shown in figure.
13) Using special tools, meas ure 1st and reverse brake
piston stroke when compressed air (400 – 800 kPa,
4 – 8 kg/cm
2, 57 – 113 psi) is brown through oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.791 – 1.489 mm (0.0311 – 0.0586 in.) 14) Install reduction drive gear (1) to transaxle case (3)
by using special tools and hydraulic press.
CAUTION!
• Do not use transaxle case as groundwork to press fit reduction drive gear.
• Do not give load more than 20 kN (2000 kg, 4410 lb) with hydraulic press. Otherwise, it
may result in damaging reduction drive
gear bearing.

NOTE
When replacing reduction drive gear, replace
it together with reduction driven gear as a
set.

Special tool
(A): 09951–18210
(B): 09944–78210
15) Install parking lock pawl (1) and spring (2). Apply A/T fluid to parking lock pawl sh aft, then insert it into
transaxle case.
[A]: Correct [B]: Incorrect
I2RH0B510268-01
I2RH0B510269-01
2. Stand that can slightly lift transaxle case.
I2RH0B510270-01
I2RH0B510271-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-153
16) Install new planetary ring gear subassembly (1) to reduction drive gear (3) by using special tools and
hydraulic press.
CAUTION!
• Do not reuse planetary ring gear subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.
• Do not use transaxle case as groundwork to press fit planetary ring gear
subassembly.
• Do not give load more than 20 kN (2000 kg, 4410 lb) with hydraulic press. Otherwise, it
may result in damaging reduction drive
gear bearing.

Special tool
(A): 09951–18210
(B): 09944–78210 17) Using a small torque
wrench, while turning to
counter drive gear 100 rpm and measure the
preload.
CAUTION!
• Do not tighten nut over the specifications so that reduction drive gear nut would not
be broken.
• Carry out this procedure on rubber mat in order not to damage transaxle case.

Reduction drive gear bearing preload measured
as starting torque
Standard: 0.05 – 0.35 N ⋅m (0.5 – 3.5 kg-cm, 0.036
– 0.253 lb-ft)
18) Caulk reduction drive gear nut (1).
19) Apply A/T fluid to planetary gear assembly (1), then fit it to planetary ring gear assembly.
2. Stand that can slightly lift transaxle case.
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1
I2RH0B510275-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-155
26) Apply A/T fluid to 2nd brake piston assembly (1), and align the projection of 2nd brake piston assembly
with the groove of transaxle case, then put together.
27) Install 2nd brake piston snap ring (1) by using special tool and hydraulic press.
CAUTION!
Do not damage 2nd brake piston assembly,
return spring subassembly, plates and discs
by pressing in 2nd brake assembly passing
through its original installing position over
0.4 mm (0.016 in.).

Special tool
(A): 09926–96050
28) After applying A/T fluid to front sun gear thrust bearing race (2), install it to front planetary sun gear
(1). 29) Apply A/T fluid to front planetary sun gear (1) and
install it to planetary gear assembly (2).
30) Install O/D and 2nd coast brake retaining plate snap ring (1).
CAUTION!
Be sure to install O/D and 2nd coast brake
retaining plate snap ring correctly in groove
of transaxle case.

31) After applying grease to slide contact face of planetary carrier thrust washer (1), install it to
planetary gear assembly.
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
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Downloaded from www.Manualslib.com manuals search engine 5B-26 Manual Transmission/Transaxle:
Input Shaft Assembly Disassembly and
Reassembly
S7RS0B5206019
Disassembly1) Remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and hydraulic press.
2) Drive out 5th gear spacer (2) and left bearing (3) from input shaft (1) using bearing puller (4) and
hydraulic press.
CAUTION!
To avoid gear tooth from being damaged,
support it at flat side of bearing puller.

3) Take out 4th gear, 4th gear needle bearing and high speed synchronizer ring.
4) Using snap ring pliers (2), remove circlip (1). 5) Drive out high speed synchronizer sleeve & hub
assembly (2) together with 3rd gear (3) from input
shaft (1) using bearing puller (4) and hydraulic press.
CAUTION!
Make sure to use flat side of bearing puller to
avoid causing damage to 3rd gear tooth.

6) Take out 3rd gear needle bearing from shaft.
7) Disassemble high speed synchronizer sleeve & hub assembly.
Reassembly 1) Clean all components thoroughly, inspect them for any abnormality and replace with new ones as
necessary.
2) To ensure lubrication of input shaft (1), air blow oil holes (2) and make sure that they are free from any
obstruction.
IYSY01521048-01
1 2
3
4
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Downloaded from www.Manualslib.com manuals search engine 5B-28 Manual Transmission/Transaxle:
8) Press-fit left bearing (2) using special tool and hammer.
Special tool
(A): 09913–70123
9) Using the same special tool at Step 8), drive in 5th
gear spacer (1).
CAUTION!
To prevent 5th gear spacer from being
distorted because of excessive compression,
do not press-fit it with left bearing at once.

Countershaft Assembly Disassembly and
Reassembly
S7RS0B5206020
Disassembly
1) Drive out left bearing cone (2) with 4th gear (3) from countershaft (1) using bearing puller (4) and
hydraulic press.
CAUTION!
• Use bearing puller and hydraulic press that will bear at least 5 ton (11,000 lb) safely.
• To avoid tooth damage, support 4th gear at flat side of bearing puller.

2) Apply bearing puller (5) to 2nd gear (4) and drive out 3rd & 4th gear spacer (2) and 3rd gear (3) together
with 2nd gear from countershaft (1) using hydraulic
press. Take out needle bearing from countershaft.
CAUTION!
• If compression exceeds 5 ton (11,000 lb), release compression once, reset bearing
puller support and then continue press
work again.
• To avoid gear tooth from being damaged, support it at flat side of bearing puller.

3) Take out 2nd gear synchronizer outer ring, center cone and inner ring.
4) Using snap ring pliers (2), remove circlip (1).
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2. Low speed synchronizer sleeve
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I6RS0C520014-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-29
5) Apply bearing puller (3) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (1)
with 1st gear using hydraulic press.
CAUTION!
To avoid gear tooth from being damaged,
support it at flat side of bearing puller.

6) Disassemble low speed synchronizer sleeve & hub assembly.
7) Take out 1st gear needle bearing from shaft.
8) Remove right bearing cone (2) using bearing puller (3), metal stick (1) and hydraulic press.
Reassembly 1) Clean all components thor oughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) To ensure lubrication of countershaft (1), air blow oil holes (2) and make sure that they are free from any
obstruction. 3) Fit low speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to each key but it is assigned as sleeve & hub
assembly.
• Size of low speed synchronizer keys and springs are the largest compared with
those of high speed and 5th speed ones.

Synchronizer key installation position
A = B
4) Install right bearing cone (1) to countershaft (2) using special tool and hammer.
Special tool
(A): 09923–78210
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[A]: 1st gear side D: Short flange
C: Key way
I3RM0A520051-01
I2RH01520062-01

Downloaded from www.Manualslib.com manuals search engine 5B-30 Manual Transmission/Transaxle:
5) Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring.
6) Drive in low speed synchronizer sleeve & hub assembly (1) using special tools and hammer.
NOTE
• Support shaft with special tool as shown in figure so that retainer of bearing cone (4)
will be free from compression.
• Make sure that synchronizer ring (2) key slots are aligned with keys while press-
fitting sleeve & hub assembly.
• Check free rotation of 1st gear (3) after press-fitting sleeve & hub assembly.

Special tool
(A): 09923–78210
(B): 09940–51710
(C): 09924–07730
(D): 09924–07710
7) Install circlip (1) and confirm that circlip is installed in groove securely.
Install needle bearing (2), apply oil to bearing.
With synchronizer outer ring (3), center cone (4) and
inner ring (5) put together and installed to 2nd gear
(6) as shown in figure. 8) Press-fit 3rd gear (2) and spacer (1) using special
tools and hydraulic press.
CAUTION!
Press-fit spacer (1) and 3rd gear (2) first, and
then 4th gear later separately so that
countershaft will not be compressed
excessively.

Special tool
(A): 09923–78210
(D): 09913–84510
9) Press-fit 4th gear (2) using the same procedure as Step 8).
10) Install left bearing cone (1) using special tools and hammer.
NOTE
For protection of right bearing cone (3),
always support shaft with special tool as
shown in figure.

Special tool
(A): 09923–78210
(E): 09913–80113
[A]: Section A – A
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3. 2nd gear
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