2008 SUZUKI SWIFT clutch special tool

Downloaded from www.Manualslib.com manuals search engine 5A-118 Automatic Transmission/Transaxle:
55) Remove one-way clutch outer race retainer (1).
56) Check one-way clutch No.2 as follows.• Ensure planetary carrier (1) rotates only in counterclockwise direction “A”, never in clockwise
direction “B”.
• If the planetary carrier rotates both ways or does not rotate either way, one-way clutch No.2
assembly will need to be replaced with new one-
way clutch No.2 assembly.
57) Remove one-way clutch No.2 assembly (1). 58) Remove planetary gear assembly (1).
59) Measure 1st and reverse brake piston stroke.
If piston stroke exce eds specified value,
disassemble, inspect and replace discs and plates.
• Using special tool, measure 1st and reserve brake piston stroke when compressed air (400 – 800
kPa, 4 – 8 kg/cm
2, 57 – 113 psi) is blown through
oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.79 – 1.49 mm (0.031 – 0.059 in.)
I2RH0B510129-01
I2RH0B510130-01
1
I4RS0A510039-01
I2RH0B510132-01
I2RH0B510133-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-123
2) Check tip clearance of both drive and driven gears.Using a feeler gauge, m easure clearance between
drive and driven gear tips. If clearance exceeds its
standard value, replace oil pump assembly.
Tip clearance between oil pump drive gear and
oil pump driven gear
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
3) Check side clearance of both gears. Using a straightedge (1) and a feeler gauge (2),
measure side clearance between gears and pump
body.
If clearance exceeds its standard value, replace oil
pump assembly.
Side clearance between gears and oil pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.0019 in.)
4) Using special tool, measure stator shaft bush (1) bore.
If measured stator shaft bush bore is out of
specifications, replace oil pump assembly with new
one.
Special tool
(A): 09900–20605
Stator shaft bush bore
Standard: 18.424 – 18.450 mm (0.7254 – 0.7264
in.) 5) Install direct clutch asse
mbly (1) to stator shaft
assembly (2), then ensure that direct clutch
assembly turns smoothly.
If unsmooth rotation or noise are found in oil pump
assembly, replace oil pump assembly with new one.
This check should also be done to input shaft
assembly and replace input shaft assembly if
necessary.
6) Using special tool, measure oil pump body bush bore.
If measured oil pump body bush (1) bore is out of
specifications, replace o il pump assembly with new
one. Torque converter also needs to be checked.
Replace torque converter, if necessary.
Special tool
(A): 09900–20605
Oil pump body bush bore
Standard: 38.113 – 38.138 mm (1.5005 – 1.5015
in.)
I2RH0B510155-01
I2RH0B510156-01
I2RH0B510157-01
I2RH0B510158-01
I2RH0B510159-01

Downloaded from www.Manualslib.com manuals search engine 5A-124 Automatic Transmission/Transaxle:
Direct Clutch Assembly ComponentsS7RS0B5106037
Direct Clutch Assembly Preliminary CheckS7RS0B5106038
Install direct clutch assembly (1) to oil pump assembly
(2) blow in air (400 – 800 kPa, 4 – 8 kg/cm2, 57 – 113
psi) through oil hole (3) of oil pump assembly with
special tool attached on uppe r surface of direct clutch
piston, and measure piston stroke of direct clutch.
If piston stroke exceeds sp ecified value, disassemble,
inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
I2RH0B510160-01
1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate
2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring
3. Input shaft subassembly 8. Shaft snap ring : Apply automatic transaxle fluid.
4. Inner O-ring 9. Direct clutch separator plate : Do not reuse.
5. Direct clutch piston 10. Direct clutch disc
I2RH0B510161-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-125
Direct Clutch Assembly Disassembly and
Reassembly
S7RS0B5106039
Disassembly1) Remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates.
2) Using special tool and hydraulic press, remove shaft snap ring (1).
Special tool
(A): 09926–98310
CAUTION!
Do not press direct clutch return spring
subassembly in over 0.7 mm (0.027 in.).
Excessive compression may cause damage
to direct clutch return spring subassembly
and/or piston.

3) Remove direct clutch re turn spring assembly (2).
4) Using a finger to block oil hole (1), apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2, 57 –
113 psi) to opposite hole, which will assist in removal
of the clutch piston. 5) Remove outer O-ring (1).
6) Remove inner O-ring (2).
7) Remove input shaft seal rings (1).
I2RH0B510162-01
I2RH0B510163-01
I2RH0B510164-01
2. Direct clutch piston
1. Input shaft subassembly
I2RH0B510165-01
I2RH0B510166-01
I2RH0B510167-01

Downloaded from www.Manualslib.com manuals search engine 5A-126 Automatic Transmission/Transaxle:
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal ring and O-ring. Apply A/T fluid before installation.
• Do not damage direct clutch return spring subassembly (1) and piston by pressing in direct
clutch return spring subassembly passing through its
original installing position over 0.7 mm (0.027 in.).
Special tool
(A): 09926–98310
• Apply A/T fluid to direct cl utch separator plates (4),
discs (3) and retaining plate (2).
• Install direct clutch separator plates (4), discs (3), retaining plate (2) and snap ring (1) to input shaft
subassembly.
• Install plate snap ring so that its both ends would be positioned in correct locations as shown in figure. • After assembly, measure direct clutch piston stroke.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
When piston stroke is out of specification, select direct
clutch retaining plate with suitable thickness from
among the following table and replace it.
Available direct clutch retaining plate thickness
I2RH0B510168-01
I2RH0B510169-01
[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
2.8 mm (0.110 in.) 4
1. Direct clutch assembly 3. Oil hole
2. Oil pump assembly
I2RH0B510170-01
I2RH0B510171-01

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