TeamSwift

This is the entire manual transmission section from the Suzuki Swift factory service manual. I fed the library photocopier about $10 in change to get all 41 pages of it. This will help complete the existing electronic version of the manual, which is entirely missing the transmission section.

7A-01 Manual Transmission (Table of Contents)

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7A-02 General Description

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7A-03 Gear Train Exploded Diagram

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7A-04 Gear Shift Mechanism

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7A-05 5th & Reverse Shift Cam

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7A-06 Diagnosis

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7A-07 On-Vehicle Service - Oil Change

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7A-08 Differential Side Oil Seal

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7A-09 Differential Side Oil Seal con't

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7A-10 Gear Shift Control

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7A-11 Gear Shift Control con't

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7A-12 Speedometer Driven Gear

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7A-13 Speedometer Driven Gear con't

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7A-14 Unit Repair Overhaul - Dismounting of Transmission

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7A-15 Remounting

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7A-16 Disassembling Unit

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7A-17 Gear Shifter, Main Shaft and Counter Shaft

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7A-18 Gear Shifter, Main Shaft and Counter Shaft con't

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7A-19 Right Case

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7A-20 Sub Assembly Service - Right Case

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7A-21 Left Case

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7A-22 Input Shaft Assembly

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7A-23 Input Shaft Assembly con't

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7A-24 Input Shaft Assembly con't

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7A-25 Countershaft Assembly

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7A-26 Countershaft Assembly con't

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7A-27 Countershaft Assembly con't

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7A-28 Gear Shifter

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7A-29 5th & Reverse Gear Shifter

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7A-30 Differential Assembly

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7A-31 Differential Assembly con't

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7A-32 Assembling Unit - Differential to Left Case

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7A-33 Differential to Left Case con't

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7A-34 Fifth Gears

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7A-35 Fifth Gears con't

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7A-36 Gear Shift & Shaft Assembly

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7A-37 Gear Shift & Shaft Assembly con't

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7A-38 Recommended Torque Specifications

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7A-39 Required Service Materials

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7A-40 Special Tools

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7A-41 Special Tools con't

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Lihtan you are a legend, I'm about to strip a MK2 box, Karma for you!

hey this is great is this for the 1.3 or the 3 cylinder? i would like to know cuz im doing a clutch job soon thanks alot-rob

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rip my poor baby sept 1994-apr 2008
91 sidekick, 4x4 2" lift 30" swampers, winch,
to come ..... performance bits.... body lift, custom bumpers

They're essentially the same, there are some differences in part numbers where the gear ratios are different, but the assembly/disassembly doesn't change.

This was scanned from the GTi factory service manual.

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TRYING TO REBUILD TRANNY AFTER ANOTHER TOOK APART.. NEED DIAGRAM.[/b]

Well the entire manual is right here in this thread, don't know what else you need. Please turn off your caps lock.

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91 Pontiac Firefly Turbo
10 Suzuki Kizashi


Alcohol, Tobacco, and Firearms
Should be the name of a convenience store, not a government agency

I have a tip for making it easier to get the nut off the counter-shaft (step 6 on page 17) without the special tool to keep the counter-shaft from spinning.

Go ahead and do steps 1 through 7 under "Gear shift, main shaft and counter shaft" to remove the shift selector first. Then you can reach into the case and move all three shift shafts up or down, locking up the gearbox. That way, the counter-shaft can't turn when you try to turn the nut.

How ya like me now?

http://www.flickr.com/photos/drimportracing/sets/72157623615093823/

For slideshow:
http://www.flickr.com/photos/drimportracing/sets/72157623615093823/show/

Click on "Show info" and pause as needed.

It took longer to photo, organize, write and post than it did to do the swap.

All mechanical expertise goes to Louis Tucker. Enjoy!!! - Dale

Thanks for all the excellent tutorial type pictures.
I realize it's a lot more work to make meaningful pics,
but it sure helps owners figure what & how to do it.

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'89 -made in Japan

Thanks to you and Louis for your great work.
If you could fix the info on the second picture; it kinda threw me for a loop.
For a minute there, it looked like you were putting in a 3.36 gear set. And for our cars, that would be a first.

A little help? Here ya go:
http://geometroforum.com/topic/3016184/3/#post247132

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DIY Broken Bolt Removal: viewtopic.php?f=22&t=41042
DIY Clutch Adjustment: viewtopic.php?f=9&t=48281
DIY Wheel Bearings: viewtopic.php?f=2&t=29003
DIY Shocks: viewtopic.php?f=10&t=45483
DIY Wheel Align: viewtopic.php?f=2&t=42479
Once you get the cars dialed-in (compression, leaks, bearings, alignment, brakes) swap in new rubber and glass, you've got something which should last for years!

Phil N Ed,
Thanks for the correction. Louis caught it too. Totally my fault. I'm dangerous with a keyboard!

Great link on the geometroforum too! - Dale

Hey all ... I came in here looking for the 5-speed manual transmssion oil capacity for my CAMI-produced '95 Pontiac Firefly (3 cyl. 1.0 litre) ... excellent resource Lihtan! Thanks for all the work you put into copying the 7A section of the manual.

Wikipedia says I have a '1995–1997 Pontiac Firefly 3dr hatchback, Gen III'
in one place (photo) http://upload.wikimedia.org/wikipedia/commons/thumb/c/c4/%2795-%2797_Pontiac_Firefly_Hatch.JPG/120px-%2795-%2797_Pontiac_Firefly_Hatch.JPG and a 'Mk4 - 95-97 (Guppy mouth) Corresponds to Generation III' in another: http://en.wikipedia.org/wiki/Suzuki_Cultus#North_America, however, I'm reasonably confident the transmission is identical to the MK2/MK3's, therefore 2.4 litres of GL-4 or GL-5 should suffice. I got most of 2 US qts of Red Line MTL SAE 70W-80 GL-4 into it yesterday, so it probably still needs a little better than 1/2 a litre more - meaning L*rdc* gets another $21.82 out of me for another bottle of MTL.

Any comments on the use of the Red Line MTL? Or the viscosity range L*rdc* supplied?

I'm trying to address slightly cranky synchro operation into 2nd and am hoping this MTL will help.

My old oil was fairly metallic-y-looking with a couple of little metal chips and there was a nice gob of metal sludge on the magnetic drain plug. But for 256,500 kms total mileage, I suppose I shouldn't complain too much.

i made a pdf from all the big images. however something would not let me upload it to the post, so if someone can do that for me ? easy to print the whole thing and view it now.
http://www.megaupload.com/?d=6KO6K4TU

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Silver 2000 Firefly 4DR; 16V SOHC, 3 to 5 speed swap, install PS and AC, remote and auto start, PL, PW, kill and start switch, Valentine 1, behind-bumper CAI, 55MM TB with coolant-bypass, polyurethane-fill engine/shifter mounts, modified to short shifter, upgraded electrical system, CS130 alternator, 90/160W headlights + relay mod, ceramic H4 plug/harness
To do: finish stereo, 4000K H4 HIDs, short block replacement
'sponsored' by Captain Crunch, Lordco, Felpro, Permatex, Royal Purple

Thank you so much TheSilverBullet for this manual transmission pdf file. This will be of very big help for my second- hand Suzuki Swift.

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Norman Summerville
:::NEXT PROJECT::: Suzuki Engine Parts Mods
:::NEXT BUY::: Suzuki Parts, Suzuki Accessories

heh, good thing i did that as the last server move killed 50% of all old images.

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Silver 2000 Firefly 4DR; 16V SOHC, 3 to 5 speed swap, install PS and AC, remote and auto start, PL, PW, kill and start switch, Valentine 1, behind-bumper CAI, 55MM TB with coolant-bypass, polyurethane-fill engine/shifter mounts, modified to short shifter, upgraded electrical system, CS130 alternator, 90/160W headlights + relay mod, ceramic H4 plug/harness
To do: finish stereo, 4000K H4 HIDs, short block replacement
'sponsored' by Captain Crunch, Lordco, Felpro, Permatex, Royal Purple

Whoa. Spoke too soon. I don't think anyone predicted Megaupload's demise. Anyhow. I would love a copy of the PDF that was here. I have been searching everywhere for one.

The first person that posts it becomes my hero.
…Thanks in advance hero.

LayCraft ... I tried uploading the file to this thread in the forum here, however, I think it is too large (8.52MB). PM me an e-mail and I'll get it to you via YouSendIt or ?
FFF

why not just upload it somewhere else and then just post the share link here
I don't have the original file anymore.

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Silver 2000 Firefly 4DR; 16V SOHC, 3 to 5 speed swap, install PS and AC, remote and auto start, PL, PW, kill and start switch, Valentine 1, behind-bumper CAI, 55MM TB with coolant-bypass, polyurethane-fill engine/shifter mounts, modified to short shifter, upgraded electrical system, CS130 alternator, 90/160W headlights + relay mod, ceramic H4 plug/harness
To do: finish stereo, 4000K H4 HIDs, short block replacement
'sponsored' by Captain Crunch, Lordco, Felpro, Permatex, Royal Purple

Don't worry. I'll post a link on the forum as soon as he sends me the file because I can host files. I will definitely share.
I just need the file now.

TheSilverBullet ... what upload site compares to Megaupload these days (for free & easy large file sharing)? emoticons x 3? ... don't worry, be happy mon ...

LayCraft ... check ur e-mail ... the YouSendIt link is:
http://www.yousendit.com/download/M3Bsc ... YlA0WjlVag
and expires 26FEB12 ...

FFF

Alright, so I'm going to leave them on my hosting for now until I can find somewhere else to put them. My hosting has been the same for years so it should stay there for a long time.

Here is the one I got from Frankenstein.
http://laycraftdesign.com/PDF/manual_transmission.pdf
Here is the one that I cleaned up and indexed. You can search this one easily.
http://laycraftdesign.com/PDF/manual_transmission%20index.pdf

actually converting the orig. jpgs to pdf file was a bit of a chore, I had to use change it to black/white and use a few irfanview extensions and etc so it could be printable.

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Silver 2000 Firefly 4DR; 16V SOHC, 3 to 5 speed swap, install PS and AC, remote and auto start, PL, PW, kill and start switch, Valentine 1, behind-bumper CAI, 55MM TB with coolant-bypass, polyurethane-fill engine/shifter mounts, modified to short shifter, upgraded electrical system, CS130 alternator, 90/160W headlights + relay mod, ceramic H4 plug/harness
To do: finish stereo, 4000K H4 HIDs, short block replacement
'sponsored' by Captain Crunch, Lordco, Felpro, Permatex, Royal Purple

Hey, I'm not complaining. Your efforts are valiant. I did see your program that you used in the metadata. I just figured people may find it handy to do the control-F thing. Pssh, who likes to read things when a computer can do the reading for you? (Illiteracy once again rears it's ugly head.)

I just pulled it into Acrobat Pro, did OCR, background cleanup, and page straightening. It's all built in and automagical if you know where to look. I only know this stuff exists because I do stuff like this for a living. I didn't do any work really it was all my computer. I swear.

Hi, I am trying to download the sections of the transmission manual but I am getting an error code instead.
What am I doing wrong? Any sugestions?
Thanks in advance Herb