Diagnostic Information And Procedures; Manual Transaxle Symptom Diagnosis; Repair Instructions; Manual Transaxle Oil Change - Suzuki Swift Sport 2004 Service & Repair Manual

Manual Transaxle Symptom Diagnosis

Condition
Gears slipping out of
mesh
Hard shifting
Noise

Manual Transaxle Oil Change

1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage.
If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.
3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.

Diagnostic Information and Procedures

Possible cause
Worn shift fork shaft
Worn shift fork or synchronizer sleeve
Weak or damaged locating springs
Worn bearings on input shaft or
countershaft
Worn chamfered tooth on sleeve and
gear
Maladjusted gear select control cable
Inadequate or insufficient lubricant
Improper clutch pedal free travel
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve or gear Replace sleeve or gear.
Worn gear shift / select control cables
joint
Distorted shift shaft
Worn gear shift / select control cables
Inadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts

Repair Instructions

S7RS0B5206001
Manual Transmission/Transaxle:
Correction / Reference Item
Replace.
Replace.
Replace.
Replace.
Replace sleeve and gear.
Adjust.
Replenish.
Replace clutch master cylinder or clutch pedal
arm.
Replace.
Replace clutch cover.
Replace.
Replace.
Replace.
Replace.
Replenish.
Replace.
Replace.
Replace.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
"A": Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Pour new specified oil until oil level reaches bottom
of oil filler plug hole (3) as shown in figure.
NOTE
It is highly recommended to use API GL-4
75W-90 gear oil.
Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Manual transaxle oil capacity
Reference: 2.0 liters (4.2/3.5 US/Imp. pt)
5B-3
S7RS0B5204001