2008 SUZUKI SWIFT Axle seal

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-137
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal rings and O-rings. Apply A/T fluid to seal rings and O-rings before installation.
• Tighten rear cover plugs to specified torque.
Tightening torque
Rear cover plug: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
• Before installing rear cover seal ring, apply A/T fluid to ring.
First, tighten seal ring to 5 mm (0.197 in.), then install
seal ring.
• Do not open rear cover seal ring too wide to attach.
• Do not damage O/D and 2nd coast brake return spring subassembly and piston by pressing in O/D
and 2nd coast brake return spring subassembly
passing through its original installing position over 1.0
mm (0.039 in.).
Special tool
(A): 09926–96030
(B): 09946–06710Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Inspection
S7RS0B5106049
O/D and 2nd Coast Brake Return Spring
Subassembly
Measure free length of O/D and 2nd coast brake return
spring subassembly.
Free length of O/D and 2nd coast brake return spring
subassembly
“a”: 18.99 mm (0.748 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

Transaxle Rear Cover Bush
Measure transaxle rear cover bush bore by using special
tool.
If measured transaxle rear cover bush bore is out of
specifications, replace transaxle rear cover with new
one. In replacement, inte rmediate shaft subassembly
also needs to be checked. Replace intermediate shaft
subassembly, if necessary.
Special tool
(A): 09900–20605
Transaxle rear cover bush bore
Standard: 13.94 – 13.96 mm (0.549 – 0.550 in.)
1. Transaxle rear cover
1. Transaxle rear cover
I2RH0B510206-01
I2RH0B510201-01
I2RH0B510207-01
I2RH0B510208-01

Downloaded from www.Manualslib.com manuals search engine 5A-144 Automatic Transmission/Transaxle:
Torque Converter Housing Disassembly and
Reassembly
S7RS0B5106057
Disassembly1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2).
2) Remove lubrication LH tube (1) and RH tube (2).
NOTE
Do not bend lubrication tube with excessive
force.

3) Remove differential side oil seal (1). 4) Remove countershaft RH bearing cup by using
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
5) Remove differential side RH bearing cup by using special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
6) Remove torque converter case plugs (1).
I2RH0B510236-01
I2RH0B510237-01
I2RH0B510238-01
I2RH0B510239-01
I2RH0B510240-01
I2RH0B510241-01

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 Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

I2RH0B510252-01
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01

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 5A-158 Automatic Transmission/Transaxle:
42) Measure O/D and 2nd coast brake piston stroke.• Measure dimension “a” from end face of transaxle case to O/D and 2nd coast brake rear plate (1)
using straightedge and micrometer caliper.
• Measure dimension “b” from O/D and 2nd coast brake piston (2) to rear cover assembly mating
surface using straightedge and micrometer
caliper.
• Calculate piston stroke from measured value of dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.)
When piston stroke is out of specification, select O/D
and 2nd coast brake rear plate with proper thickness
from among the following table and replace it.
Available O/D and 2nd coast brake rear plate
thickness
43) After applying A/T fluid to new 2nd brake gaskets (1), install them to transaxle case (2).
44) After applying A/T fluid to reverse clutch drum thrust bearing (1), install it to forward and reverse clutch
assembly (2).
45) Remove sealant attached to mating surface of transaxle rear cover (1) completely.
46) Apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Thickness Identification mark
1.8 mm (0.071 in.) 1
2.0 mm (0.079 in.) 2
2.2 mm (0.087 in.) 3
2.4 mm (0.094 in.) 4
2.6 mm (0.102 in.) 5
I2RH0B510298-01
I2RH0B510299-01
I2RH0B510300-01
“A” 2
1
I2RH0B510301-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-161
60) Measure input shaft thrust play.Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
When input shaft thrust play is out of specification,
select input shaft front th rust bearing with proper
thickness from among the following table and
replace it.
Available input shaft front thrust bearing
thickness
61) After applying A/T fluid to new O-ring, fit it to breather union (2). Then install breather union to
transaxle case.
62) Install breather hose (1). 63) Wipe off and clean mating surface between
transaxle case (1) and torque converter housing.
64) Apply sealant to torque converter housing by using a nozzle (2) as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
65) Install torque converter housing to transaxle case, tighten bolts to specified torque.
CAUTION!
Apply sealant to threads of four bolts shown
in figure before tightening.

“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Tightening torque
Torque converter housing bolt (a): 29 N·m (2.9
kgf-m, 21 lb-ft)
Thickness
Outside
diameter Inside diameter
3.45 mm
(0.14 in.) 48.5 mm
(1.90 in.) 32.9 mm
(1.30 in.)
4.05 mm
(0.16 in.) 48.5 mm
(1.90 in.) 32.5 mm
(1.28 in.)
I2RH0B510313-01
I2RH0B510314-01
1 2
“A”
I2RH0B510315-01
I3RM0B510069-01