Suzuki Esteem, Swift 1994-02

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Battery cables
     
    Battery and tray
     
    Clutch cable adjusting nut, joint pin from the cable and cable from the bracket
     
    All the wiring harness clamps and connectors involved with the transaxle removal, tag if necessary for location to aid during installation
     
    Speedometer cable boot, case clip and cable from the case
     
    Radiator outlet pipe from the transmission side cover, on Swift models
     
    Transaxle retaining bolts
     
    Starter
     
    Fender apron extension on the left side
     
    Bolts connecting the exhaust pipe to the exhaust manifold and disconnect the joint
     

  6.  
  7. On Esteem models, with the engine supported, remove the vehicle center mounting member by removing the 7 nuts and 4 bolts.

    Gearshift control shaft nut and bolt
     
    Control shaft from the gearshift control shaft
     
    Extension rod nut and washers
     
    Clutch housing lower plate
     
    Sway bar
     
    Left and right front wheels
     
    Left and right ball joints
     
    Left and right halfshafts
     
    Transaxle stiffener
     
    Transmission to engine bolt and nut
     
    Engine rear mounting bracket bolts
     

  8.  
  9. Install an engine support.
  10.  
  11. Support the transaxle with a suitable jack.
  12.  
  13. Remove the left engine mounting bracket and stiffener.
  14.  
  15. Lower the transaxle with the engine attached. Pull the transaxle straight out toward the left side.
  16.  
  17. Lower and remove the transaxle.
  18.  

To install:

  1. Install or connect the following:

    Transaxle from the left side of the vehicle. Use care when inserting the pilot shaft into the clutch assembly. If the spline on the input shaft does not align with the clutch assembly spline, turn the crankshaft slightly to aid in spline alignment.
     

  2.  
  3. Raise the transaxle and engine.
    NOTE
    Before installing the bolts into the rear mounting bracket, apply sealant to the bolt threads.



    Left engine mounting bracket and stiffener. Tighten the bolts to 29-43 ft. lbs. (40-60 Nm).
     
    Rear engine mounting bracket bolts and tighten them to 29-43 ft. lbs. (40-60 Nm)
     



    Transmission-to-engine bolt and nut. Tighten the nut and bolt to 29-43 ft. lbs. (40-60 Nm)
     

  4.  
  5. On Esteem models, install the center member on the vehicle and install the 7 nuts and 4 bolts. Tighten the bolts and nuts as follows:
    1. Center member-to-radiator support: 33 ft. lbs. (45 Nm).
    2.  
    3. Center member-to-crossmember: 33 ft. lbs. (45 Nm).
    4.  
    5. Engine mounts-to-center member nuts: 40 ft. lbs. (55 Nm).
    6.  

  6.  
  7. Install or connect the following:

    Transaxle stiffener
     

  8.  
  9. Lower the transaxle supporting jack.

    Left and right halfshafts
     
    Ball joints
     
    Sway bar
     
    Clutch housing lower plate
     
    Extension rod nut and washers. Tighten the rod nut to 18-28 ft. lbs. (25-40 Nm).
     
    Control shaft on gearshift
     
    Gearshift control shaft bolt and nut. Tighten the gearshift control shaft bolt and nut to 11-14 ft. lbs. (15-20 Nm).
     
    Exhaust pipe to the manifold and install the bolts. Tighten the bolts to 29-36 ft. lbs. (40-50 Nm).
     
    Left fender apron extension
     

  10.  
  11. Refill the transaxle with the recommended lubricant.
  12.  
  13. Remove the engine support fixture.
  14.  
  15. Install or connect the following:

    Starter
     
    Transaxle retaining bolts. Tighten the retaining bolts to 29-43 ft. lbs. (40-60 Nm).
     
    Remaining components in the reverse order of removal
     
    Negative battery cable and the ground strap on the transaxle
     

  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Battery cables
     
    Battery and tray
     
    Clutch cable adjusting nut, joint pin from the cable and cable from the bracket
     
    All the wiring harness clamps and connectors involved with the transaxle removal, tag if necessary for location to aid during installation
     
    Speedometer cable boot, case clip and cable from the case
     
    Radiator outlet pipe from the transmission side cover, on Swift models
     
    Transaxle retaining bolts
     
    Starter
     
    Fender apron extension on the left side
     
    Bolts connecting the exhaust pipe to the exhaust manifold and disconnect the joint
     

  6.  
  7. On Esteem models, with the engine supported, remove the vehicle center mounting member by removing the 7 nuts and 4 bolts.

    Gearshift control shaft nut and bolt
     
    Control shaft from the gearshift control shaft
     
    Extension rod nut and washers
     
    Clutch housing lower plate
     
    Sway bar
     
    Left and right front wheels
     
    Left and right ball joints
     
    Left and right halfshafts
     
    Transaxle stiffener
     
    Transmission to engine bolt and nut
     
    Engine rear mounting bracket bolts
     

  8.  
  9. Install an engine support.
  10.  
  11. Support the transaxle with a suitable jack.
  12.  
  13. Remove the left engine mounting bracket and stiffener.
  14.  
  15. Lower the transaxle with the engine attached. Pull the transaxle straight out toward the left side.
  16.  
  17. Lower and remove the transaxle.
  18.  

To install:

  1. Install or connect the following:

    Transaxle from the left side of the vehicle. Use care when inserting the pilot shaft into the clutch assembly. If the spline on the input shaft does not align with the clutch assembly spline, turn the crankshaft slightly to aid in spline alignment.
     

  2.  
  3. Raise the transaxle and engine.
    NOTE
    Before installing the bolts into the rear mounting bracket, apply sealant to the bolt threads.



    Left engine mounting bracket and stiffener. Tighten the bolts to 29-43 ft. lbs. (40-60 Nm).
     
    Rear engine mounting bracket bolts and tighten them to 29-43 ft. lbs. (40-60 Nm)
     



    Transmission-to-engine bolt and nut. Tighten the nut and bolt to 29-43 ft. lbs. (40-60 Nm)
     

  4.  
  5. On Esteem models, install the center member on the vehicle and install the 7 nuts and 4 bolts. Tighten the bolts and nuts as follows:
    1. Center member-to-radiator support: 33 ft. lbs. (45 Nm).
    2.  
    3. Center member-to-crossmember: 33 ft. lbs. (45 Nm).
    4.  
    5. Engine mounts-to-center member nuts: 40 ft. lbs. (55 Nm).
    6.  

  6.  
  7. Install or connect the following:

    Transaxle stiffener
     

  8.  
  9. Lower the transaxle supporting jack.

    Left and right halfshafts
     
    Ball joints
     
    Sway bar
     
    Clutch housing lower plate
     
    Extension rod nut and washers. Tighten the rod nut to 18-28 ft. lbs. (25-40 Nm).
     
    Control shaft on gearshift
     
    Gearshift control shaft bolt and nut. Tighten the gearshift control shaft bolt and nut to 11-14 ft. lbs. (15-20 Nm).
     
    Exhaust pipe to the manifold and install the bolts. Tighten the bolts to 29-36 ft. lbs. (40-50 Nm).
     
    Left fender apron extension
     

  10.  
  11. Refill the transaxle with the recommended lubricant.
  12.  
  13. Remove the engine support fixture.
  14.  
  15. Install or connect the following:

    Starter
     
    Transaxle retaining bolts. Tighten the retaining bolts to 29-43 ft. lbs. (40-60 Nm).
     
    Remaining components in the reverse order of removal
     
    Negative battery cable and the ground strap on the transaxle
     

  16.  

 
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