2008 SUZUKI SWIFT Enter

Downloaded from www.Manualslib.com manuals search engine 5A-166 Automatic Transmission/Transaxle:
91) Bend dents of lock washer (1) in order to prevent displacement of lock washer.
92) Install manual select lever (1). Tightening torque
Manual select lever nut (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
93) Install engine mounting LH bracket (1). Tightening torque
Engine mounting LH bracket bolt (a): 55 N·m (
5.5 kgf-m, 40.0 lb-ft) 94) Install torque converter (3) noting the following
points.
CAUTION!
• Before installing converter, make sure that its pump hub portion is free from nicks,
burrs or damage which may cause oil seal
to leak.
• Be very careful not to drop converter on oil pump gear. Damage in gear, should it
occur, may cause a critical trouble.

• Install torque converter aligning grooves (1) of torque converter and projection (2) of oil pump
drive gear.
• Install torque converter, using care not to damage oil seal of oil pump.
• After installing torque converter, check that distance “a” is within specification.
Torque converter installing position
“a”: More than 19.9 mm (0.783 in.)
• Check torque converter for smooth rotation.
• Apply grease around cup (6) at the center of torque converter.
“C”: Grease 99000–25011 (SUZUKI Super
Grease A)
1
I3RM0B510075-01
1
(a)
I3RM0B510076-01
I3RM0B510077-01
4. Flange nut 5. Torque converter housing
I2RH0B510337-01

Downloaded from www.Manualslib.com manuals search engine 5B-4 Manual Transmission/Transaxle:
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Differential Side Oil Seal ReplacementS7RS0B5206002
1) Lift up vehicle and drain transaxle oil.
2) Remove front drive shaft and/or center shaft referring to “Front Driv e Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
4) Install oil seal (1) facing its spring side inward. Use special tool and hammer for installation.
Special tool
(A): 09913–85210
5) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make
sure of its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
6) Insert front drive shaft and/or center shaft referring to “Front Drive Shaft A ssembly Removal and
Installation in Section 3A”.
7) Fill transaxle oil as specified referring to “Manual Transaxle Oil Change”, and make sure that oil has
been sealed with oil seal.
I4RS0A520001-01
(A)
1
I4RH01520003-01
IYSY01520005-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Manual Transaxle Unit Dismounting and
Remounting
S7RS0B5206009
Dismounting1) Drain coolant and transaxle oil.
2) Remove coolant reservoir with reservoir hose.
3) Remove battery and tray.
4) Remove air cleaner case and resonator.
5) Disconnect gear shift and gear select control cables (1) while pressing claws (2) of clip (3).
6) Disconnect back up light switch coupler and undo wiring harness clamps.
7) Remove ground cable from transaxle.
8) Remove clutch operating cylinder with fluid hose from transaxle.
9) Remove water inlet No.2 pipe from transaxle.
10) Remove starting motor re ferring to “Starting Motor
Dismounting and Remounting in Section 1I”.
11) Remove transaxle to engine bolts (1) of upper side. 12) Support engine using supporting device (1).
CAUTION!
Do not apply supporting device to projection
part A. If do so, it may be deformed.

13) Remove front drive shafts and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
14) Remove exhaust No.2 pipe referring to “Exhaust Pipe and Muffler Removal a nd Installation in Section
1K”.
15) Remove clutch housing lower plate (1).
1
2
3
I7RS0A521003-01
1
1
I4RS0A520018-01
1
A
I4RS0A520019-01
1I4RS0A520020-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-25
Input Shaft and Countershaft ComponentsS7RS0B5206018
I3RM0B521010-01
1. Input shaft12. Input shaft left bearing 23. 2nd gear synchronizer center cone
2. Oil seal : Apply grease 99000-25011 to oil seal lip. 13. Circlip
24. 2nd gear synchronizer inner ring
3. Input shaft right bearing 14. 5th gear spacer 25. Circlip
4. Input shaft 3rd gear 15. Countershaft right bearing 26. Countershaft 2nd gear
5. Needle bearing 16. Countershaft 27. Countershaft 3rd gear
6. High speed synchronizer ring 17. Countershaft 1st gear 28. 3rd & 4th gear spacer
7. High speed synchronizer spring 18. 1st gear synchronizer ring 29. Countershaft 4th gear
8. High speed synchronizer sleeve & hub 19. Low speed synchronizer spring 30. Countershaft left bearing
9. High speed synchronizer key 20. Low speed synchronizer sleeve & hub : Do not reuse.
10. Circlip 21. Low speed synchronizer key : Apply transaxle oil.
11. Input shaft 4th gear 22. 2nd gear synchronizer outer ring

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).
I4RH01520032-01
I2RH01520054-01
2. Low speed synchronizer sleeve
I2RH01520055-01
I6RS0C520014-01

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
I4RH01520057-01
I2RH01520064-01
3. 2nd gear
I2RH01520065-01
I2RH01520066-01

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 5C-10 Clutch:
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts, compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
4) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft li ttle by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S7RS0B5306015
Input Shaft Bearing
Check bearing (1) for smooth ro tation and replace it if
abnormality is found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to hav e reached service limit at
any of rivet holes (2), repl ace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)
I4RS0A530017-01
I4RS0A530018-01
I3RM0A530014-01
I4RS0A530019-01