Swift Clutch And Transmission
Manual Transmission
General Description
Manual Transaxle Construction and Servicing
S4RS0A5201001
The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs and three shafts (input shaft, countershaft and reverse gear shaft). All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd gear, while the high speed synchronizer sleeve & hub is done on input shaft and engaged with input shaft 3rd gear or 4th gear. The 5th speed synchronizer sleeve & hub on input shaft is engaged with input shaft fifth gear mounted on the input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse shift braking device is used.
The device utilizes the 5th synchromesh, which is the lever synchro type, to apply the brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of shifting to 2nd gear.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are attached to the front wheels.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling. Further, care must be taken to adjust preload of countershaft taper roller bearings. New synchronizer rings are prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.
I3RM0B521001-
| 1. 5th speed sleeve & hub | 8. Reverse idler gear | 15. Countershaft 3rd gear |
|---|---|---|
| 2. Input shaft 5th gear | 9. Input shaft | 16. Countershaft 2nd gear |
| 3. Input shaft 4th gear | 10. Right case | 17. Low speed synchronizer sleeve & hub |
| 4. High speed synchronizer sleeve & hub | 11. Side cover | 18. Countershaft 1st gear |
| 5. Input shaft 3rd gear | 12. Countershaft 5th gear | 19. Final gear |
| 6. Left case | 13. Countershaft 4th gear | 20. Differential case |
| 7. Reverse gear shaft | 14. Countershaft | 21. Vehicle speed sensor rotor |
Table Caption: This table lists components of a transmission, likely for a vehicle, categorized by their location or function within the gearbox and differential assembly.
Diagnostic Information and Procedures
Manual Transaxle Symptom Diagnosis
Manual Transaxle Oil Change
S4RS0A5206001
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- Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
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- 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.
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- Remove oil filler plug (2).
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- Remove drain plug (1), and drain old oil.
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- Apply sealant to thread of drain plug (1), and tighten it to specified torque.
'A': Sealant 99000-31260
Tightening torque Transaxle oil drain plug (a): 21 N·m (2.1 kg-m, 15.5 lb-ft)
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- Pour new specified oil until oil level reaches bottom of oil filler plug hole (3) as shown in figure.
S4RS0A5204001
| Condition | Possible cause | Correction / Reference Item |
|---|---|---|
| Gears slipping out of mesh | Worn shift fork shaft | Replace. |
| Worn shift fork or synchronizer sleeve | Replace. | |
| Weak or damaged locating springs | Replace. | |
| Worn bearings on input shaft or countershaft | Replace. | |
| Worn chamfered tooth on sleeve and gear | Replace sleeve and gear. | |
| shifting | Maladjusted gear select control cable | Adjust. |
| Inadequate or insufficient lubricant | Replenish. | |
| Improper clutch pedal free travel | Replace clutch master cylinder or clutch pedal arm. | |
| Distorted or broken clutch disc | Replace. | |
| Damaged clutch pressure plate | Replace clutch cover. | |
| Worn synchronizer ring | Replace. | |
| Worn chamfered tooth on sleeve or gear | Replace sleeve or gear. | |
| Worn gear shift / select control cables joint | Replace. | |
| Distorted shift shaft | Replace. | |
| Worn gear shift / select control cables | Replace. | |
| Noise | Inadequate or insufficient lubricant | Replenish. |
| Damaged or worn bearing(s) | Replace. | |
| Damaged or worn gear(s) | Replace. | |
| Damaged or worn synchronizer parts | Replace. |
Table Caption: This table lists common automotive transmission problems, their possible causes, and the corresponding corrective actions or parts to reference. It covers issues like gears slipping, difficulty shifting, and noise.
Repair Instructions
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.)
Transaxle oil capacity (Reference)
: 2.2 liters (4.8/3.9 US/Imp. pt)
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- Apply sealant to thread of level / filler plug, and then tighten it to specified torque.
'A': Sealant 99000-31260
Tightening torque Transaxle oil level / filler plug (b): 21 N·m (2.1 kg-m, 15.5 lb-ft)
I4RS0A520001-
Differential Side Oil Seal Replacement
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- Lift up vehicle and drain transaxle oil.
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- Remove front drive shaft and/or center shaft referring to 'Front Drive Shaft Assembly Removal and Installation: in Section 3A'.
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- Remove oil seal (1) using special tool.
Special tool (A): 09913-50121
I4RH01520003-
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- Install oil seal (1) facing its spring side inward. Use special tool and hammer for installation.
Special tool (A): 09913-85210
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- 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 99000-25010
IYSY01520005-
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- Insert front drive shaft and/or center shaft referring to 'Front Drive Shaft Assembly Removal and Installation: in Section 3A'.
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- Fill transaxle oil as specified referring to 'Manual Transaxle Oil Change: ', and make sure that oil has been sealed with oil seal.
Gear Shift Control Lever and Cable Components
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**Table Caption: This table lists parts and specifications
