2006 SUZUKI SX4 manual transaxle oil

Downloaded from www.Manualslib.com manuals search engine 5A-160 Automatic Transmission/Transaxle:
94) Install manual select lever (1).
Tightening torque
Manual select lever nut (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
95) Install engine mounting LH bracket (1). Tighten
engine mounting LH bracket bolts and nut to
specified torque referring to “Engine Mountings
Components in Section 1D”.
96) 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(a)I2RH0B510335-01
1
I5RW0C510058-01
4. Flange nut
5. Torque converter housing
I2RH0B510337-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-161
Specifications
Tightening Torque SpecificationsS6RW0D5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
A/T fluid drain plug 17 1.7 12.5) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor (VSS) bolt 13 1.3 9.5) / )
Input shaft speed sensor bolt 5.5 0.55 4.0) / )
Valve body harness connector bolt 5.5 0.55 4.0) / )
Shift solenoid bolt 11 1.1 8.0)
Oil strainer bolt 10 1.0 7.5) / )
Oil pan bolt 7.0 0.7 5.0) / )
Engine oil pan bolt 55 5.5 40.0)
Transaxle and engine fastening bolt 85 8.5 61.5)
Transaxle and engine fastening nut 85 8.5 61.5)
Drive plate to torque converter bolt 19 1.9 14.0)
Transaxle housing lower plate bolt 11 1.1 8.0)
Oil pump subassembly bolt 10 1.0 7.5)
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 11 1.1 8.0)
Final gear bolt 78 7.8 56.5)
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 33 3.3 24.0) / ) / )
Manual detent spring bolt 10 1.0 7.5)
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 25 2.5 18.0)
Fluid reservoir LH plate bolt 10 1.0 7.5)
Oil pump assembly bolt 25 2.5 18.0)
Transaxle case plug 7.5 0.75 5.5)
Valve body bolt 11 1.1 8.0)
Fluid cooler pipe union 25 2.5 18.0)
Fluid cooler pipe union bolt 35 3.5 25.5)
Fluid cooler pipe bracket bolt 10 1.0 7.5)
Fluid filler tube bolt 10 1.0 7.5)
Select cable bracket bolt 23 2.3 17.0)
Select cable clamp bolt 13 1.3 9.5)
Transmission range sensor lock nut 7 0.7 5.0)
Manual select lever nut 13 1.3 9.5)

Downloaded from www.Manualslib.com manuals search engine 5A-162 Automatic Transmission/Transaxle:
Special Tools and Equipment
Recommended Service MaterialS6RW0D5108001
NOTE
Required service material is also described in the following.
“Select Cable Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Direct Clutch Assembly Components”
“Forward and Reverse Clutch Assembly Components”
“2nd Brake Piston Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Countershaft Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Special ToolS6RW0D5108002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / )
SUZUKI Super Grease C P/No.: 99000–25030) / ) / ) / ) / ) / )
Sealant SUZUKI Bond No.1216B P/No.: 99000–31230) / ) / )
09900–20605 09900–20607
Dial calipers (1/100 mm, 10-
34 mm)Dial gauge
) / ) / )) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )
09900–20701 09913–50121
Magnetic stand Oil seal remover
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )) / )
09913–61510 09913–70123
Bearing puller Bearing installing tool
)) / )
09913–75510 09913–75810
Bearing installer Bearing installer
) / )) / )

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-163
09913–84510 09913–85210
Bearing installer Bearing installer
) / ) / ) / ))
09923–78210 09924–74510
Bearing installer Bearing and oil seal handle
)) / ) / ) / )
09925–37811–001 09925–88210
Oil pressure gauge Bearing puller attachment
)) / )
09925–98210 09925–98221
Input shaft bearing installer Bearing installer
))
09926–37610 09926–37610–001
Bearing remover Bearing puller
) / )) / )
09926–37610–002 09926–37610–003
Bearing puller attachment Bearing remover attachment
) / )) / )
09926–58010 09926–96030
Bearing remover attachment Clutch spring compressor
No.7
)) / )
09926–96050 09926–97610
Brake piston compressor Spring compressor
) / )) / )

Downloaded from www.Manualslib.com manuals search engine 5A-164 Automatic Transmission/Transaxle:
09926–97620 09926–98310
Spring compressor Clutch spring compressor
) / )) / )
09928–06050 09942–15511
Differential preload adapter Sliding hammer
) / )) / ) / ) / )
09944–78210 09944–88220
Bearing installer support Oil seal installer
) / )) / ) / ) / )
09944–96011 09946–06710
Bearing outer race remover Transfer bearing dummy
) / ) / ) / )) / )
09951–18210 09952–06020
Oil seal remover & installer
No. 2Dial gauge plate No.2
) / )) / ) / ) / )
SUZUKI scan tool (SUZUKI-
SDT)
—
This kit includes following
items. 1. SUZUKI-SDT 2.
DLC3 cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case ) / )
1
2
34
56

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-5
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS6RW0D5204001
Repair Instructions
Manual Transaxle Oil Level CheckS6RW0D5206001
1) Lift up vehicle and check oil leakage. Repair leaky
point, if any.
2) Remove oil level / filler plug (1) and check oil
contamination and oil level is lower end of oil level /
filler plug hole (2).
If oil is excessive dirty or insufficient, replace oil or
pour specified oil up to plug hole.
3) 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 (a): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Condition Possible cause Correction / Reference Item
Gears slipping out of
meshWorn shift fork shaftReplace
Worn shift fork or synchronizer sleeveReplace
Weak or damaged locating springsReplace
Worn bearings on input shaft or
countershaftReplace
Worn chamfered tooth on sleeve and
gearReplace sleeve and gear
Hard shiftingInadequate lubricantReplenish
Improper clutch pedal free travelReplace clutch arm or master cylinder
Distorted or broken clutch discReplace
Damaged clutch pressure plateReplace clutch cover
Worn synchronizer ringReplace
Worn chamfered tooth on sleeve or gearReplace sleeve or gear
Worn gear shift control shaft joint bushReplace
Distorted shift shaftReplace
Broken gear shift / select control cablesReplace
NoiseInadequate or insufficient lubricantReplenish
Damaged or worn bearing(s)Replace
Damaged or worn gear(s)Replace
Damaged or worn synchronizer partsReplace
I5RW0A520004-01

Downloaded from www.Manualslib.com manuals search engine 5B-6 Manual Transmission/Transaxle:
Manual Transaxle Oil ChangeS6RW0D5206002
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check 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 level / filler plug (2).
4) Remove drain plug (1), and drain old oil.
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: 2.5 liters (5.3/4.4 US/lmp. pt.)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)
I5RW0A520005-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-7
Differential Side Oil Seal ReplacementS6RW0D5206003
1) Lift up vehicle and drain transaxle oil.
2) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove oil seal (1) by using special tool.
Special tool
(A): 09913–50121
4) Install a new oil seal (1) by using special tool.
NOTE
• When installing oil seal, face its spring
side inward.
• Install oil seal horizontally to surface of
case.

Special tool
(A): 09913–75810
(B): 09913–75510
Distance between case and right oil seal for 2WD
“a”: 9.5 – 10.5 mm (0.37 – 0.41 in.)
Distance between case and left oil seal
“b”: 0 – 1.0 mm (0 – 0.04 in.)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 drive shaft assembly and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
7) Pour transaxle oil referring to “Manual Transaxle Oil
Change”.
(A)
1I5RW0A520006-02
“b”
“a”
1, “A”
(A)(B)
I5RW0A520051-01