2006 SUZUKI SX4 clutch

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-141
3) Install new differential side oil seal to transaxle case
by using special tools.
Special tool
(A): 09913–75810
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip.
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S6RW0D5106057
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the above conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored,
replace all discs.
• Before assembling new discs, soak them
in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discoloration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return springs.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.

(A)“a”
“A”
I5RW0C510066-02
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01

Downloaded from www.Manualslib.com manuals search engine 5A-142 Automatic Transmission/Transaxle:
One-way clutch No.1 assembly
1) Install one-way clutch No.1 assembly (2) to rear
planetary sun gear subassembly (1).
2) Securing rear planetary sun gear subassembly,
ensure that one-way clutch No.1 assembly rotates
only in one direction.
If the one-way clutch rotates in both directions or it
does not rotate in either direction, replace it with new
one.
Adjustment
Differential side bearing preload
1) After applying A/T fluid to differential assembly, fit it
to transaxle case.
2) Install torque converter housing to transaxle case,
then tighten bolts (1) to specified torque.
Tightening torque
Torque converter housing bolt (a): 33 N·m (3.3
kgf-m, 24.0 lb-ft)3) Measure bearing preload (a) by using a special tool.
Special tool
(A): 09928–06050
Differential side bearing preload (a) measured as
starting torque
In the case of new bearing: 0.78 – 1.37 N⋅m (7.9 –
13.9 kg-cm, 0.58 – 1.01 lb-ft)
In the case of reused bearing: 0.39 – 0.69 N⋅m
(3.9 – 6.9 kg-cm, 0.29 – 0.51 lb-ft)
4) If bearing preload is out of specification, select shim
with suitable thickness from among the list below
and replace it. Then adjust differential side bearing
preload within specification.
Available shim thickness
NOTE
Record measured differential side bearing,
because it is necessary to adjust
countershaft bearing preload.

5) Remove differential assembly.
I2RH0B510254-01
I2RH0B510255-01
Thickness Identification mark
1.80 mm (0.070 in.) A
1.85 mm (0.072 in.) B
1.90 mm (0.074 in.) C
1.95 mm (0.076 in.) D
2.00 mm (0.078 in.) E
2.05 mm (0.080 in.) F
2.08 mm (0.081 in.) G
2.11 mm (0.083 in.) H
2.14 mm (0.084 in.) J
2.17 mm (0.085 in.) K
2.20 mm (0.087 in.) L
2.23 mm (0.088 in.) M
2.26 mm (0.089 in.) N
2.29 mm (0.090 in.) P
2.32 mm (0.091 in.) Q
2.35 mm (0.092 in.) R
2.40 mm (0.094 in.) S
2.45 mm (0.096 in.) T
2.50 mm (0.098 in.) U
2.55 mm (0.100 in.) V
2.60 mm (0.102 in.) W
2.65 mm (0.104 in.) X
2.70 mm (0.106 in.) Y
I2RH0B510256-01

Downloaded from www.Manualslib.com manuals search engine 5A-144 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS6RW0D5106058
CAUTION!
• Automatic transaxle consists of highly
precise parts. As even flaw in small part
may cause oil leakage or decrease in
function, check each part carefully before
installation.
• Clean all parts with compressed air. Never
use wiping cloths or rags.
• Before assembling new clutch or brake
discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding
or rotating surfaces of the parts before
assembly.
• Use Suzuki Super Grease “C” to retain
parts in place.
• Be sure to install thrust bearings and races
in correct direction and position.
• Make sure that snap ring ends are not
aligned with one of cutouts and are
installed in groove correctly.
• Do not use adhesive cements on gaskets
and similar parts.
• Be sure to torque each bolt and nut to
specification.

1) Install new manual shift shaft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.75 – 1.25 mm (0.03 – 0.05 in.)2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl rod (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever
(1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using
spring pin remover with 3 mm (0.12 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
I2RH0B510258-01
I2RH0B510259-01
I2RH0B510260-01
I2RH0B510261-01

Downloaded from www.Manualslib.com manuals search engine 5A-148 Automatic Transmission/Transaxle:
20) Check for correct installation of planetary gear
assembly as follows.
Measure the distance “a” by using micrometer
caliper (1) and straightedge (2). If measured value is
out of specification, remove planetary gear assembly
and reinstall it properly.
Distance between planetary gear assembly and
mating surface of transaxle case
“a”: More than 49.9 m (1.965 in.)
21) Apply A/T fluid to one-way clutch No.2 assembly (1),
then install it to planetary gear assembly. After that,
ensure that planetary carrier rotates only in
counterclockwise direction “A”, not in clockwise
direction “B”.22) Install one-way clutch outer race retainer (1).
23) Apply A/T fluid to new brake drum gasket (1), then
install it to transaxle case.
24) Apply A/T fluid to 2nd brake retaining plate (1), discs
(2) and separator plates (3), then install them to
transaxle case.
25) Install 2nd brake return spring subassembly (1) to
transaxle case.
“a”
“a”
2
1
I2RH0B510276-01
I2RH0B510277-01
I2RH0B510278-01
I2RH0B510279-01
2
3
1
I2RH0B510280-01
1
I2RH0B510281-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-149
26) Apply A/T fluid to 2nd brake piston assembly (1), and
align the projection of 2nd brake piston assembly
with the groove of transaxle case, then put together.
27) Install 2nd brake piston snap ring (1) by using
special tool and hydraulic press.
CAUTION!
Do not damage 2nd brake piston assembly,
return spring subassembly, plates and discs
by pressing in 2nd brake assembly passing
through its original installing position over
0.4 mm (0.016 in.).

Special tool
(A): 09926–96050
28) Check 2nd brake piston stroke by measuring
clearance between 2nd brake separator plate (1)
and piston (2) with feeler gauge (3).
If clearance, that is, piston stroke is out of
specification replace clutch discs and plates with
new ones.
CAUTION!
When brake disc, retaining plate and/or
separator plate of 2nd brake have been
replaced, all learned contents, which have
been stored in TCM memory by executing
learning control, should be initialized
referring to “Learning Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

2nd brake piston stroke
Standard: 0.40 – 1.25 mm (0.016 – 0.049 in.)
29) After applying A/T fluid to front sun gear thrust
bearing race (2), install it to front planetary sun gear
(1).
30) Apply A/T fluid to front planetary sun gear (1) and
install it to planetary gear assembly (2).
I2RH0B510282-01
I2RH0B510283-01
32
1
I2RH0B510284-01
I2RH0B510285-01
I2RH0B510286-01

Downloaded from www.Manualslib.com manuals search engine 5A-150 Automatic Transmission/Transaxle:
31) Install O/D and 2nd coast brake retaining plate snap
ring (1).
CAUTION!
Be sure to install O/D and 2nd coast brake
retaining plate snap ring correctly in groove
of transaxle case.

32) After applying grease to slide contact face of
planetary carrier thrust washer (1), install it to
planetary gear assembly.
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
33) Apply A/T fluid to one-way clutch No.1 assembly (3)
and install one-way clutch No.1 assembly (3) to rear
planetary sun gear subassembly (2).
34) Apply A/T fluid to planetary gear thrust bearing (1),
then install it to one-way clutch No.1 assembly (3).35) After applying A/T fluid to rear planetary sun gear
subassembly and one-way clutch No.1 assembly (1),
install them in transaxle case (2).
36) After applying A/T fluid to rear sun gear thrust
bearing race (1), install it to rear planetary sun gear
(2).
37) After applying A/T fluid to rear sun gear thrust
bearing (1), install it to forward clutch hub (2).
38) After applying A/T fluid to forward clutch hub (1),
install it in transaxle case (2).
I2RH0B510287-01
I2RH0B510288-01
I2RH0B510289-01
I2RH0B510290-01
I2RH0B510291-01
I2RH0B510292-01
I2RH0B510293-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-151
39) After applying A/T fluid to intermediate shaft thrust
bearing rear race (3), thrust bearing (2) and front
race (1), install them to forward and reverse clutch
assembly (4).
Bearing race dimension
40) Apply A/T fluid to forward and reverse clutch
assembly (1).
Install forward and reverse clutch assembly while
rotating clockwise and counterclockwise frequently
to fit clutch discs to mating hubs.
NOTE
Before installation, align teeth of forward and
reverse clutch discs to facilitate installation.

41) Check for correct installation of forward and reverse
clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
forward and reverse clutch assembly, forward clutch
hub, rear planetary sun gear subassembly and one-
way clutch No.1 assembly, and reinstall them
properly.
Distance between forward and reverse clutch
assembly and mating surface of transaxle case
“a”: 27.1 – 29.4 mm (1.067 – 1.157 in.)
42) After applying A/T fluid to O/D and 2nd coast brake
retaining plate (4), separator plate (3), discs (2) and
rear plate (1), install them to transaxle case (5). Front race Rear race
Outside
diameter30.6 mm (1.20 in.) 28.2 mm (1.11 in.)
Thickness 2.0 mm (0.08 in.) 2.0 mm (0.08 in.)
I2RH0B510294-01
I2RH0B510295-01
“a”
“a”
1
2
I2RH0B510296-01
I2RH0B510297-01

Downloaded from www.Manualslib.com manuals search engine 5A-152 Automatic Transmission/Transaxle:
43) Measure O/D and 2nd coast brake piston stroke.
• Measure dimension “a” from end face of transaxle
case to O/D and 2nd coast brake rear plate (1)
using straightedge and micrometer caliper.
• Measure dimension “b” from O/D and 2nd coast
brake piston (2) to rear cover assembly mating
surface using straightedge and micrometer
caliper.
• Calculate piston stroke from measured value of
dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.)
When piston stroke is out of specification, select O/D
and 2nd coast brake rear plate with proper thickness
from among the following table and replace it.
CAUTION!
When brake disc, retaining plate, separator
plate and/or rear plate of O/D and 2nd coast
brake have been replaced, all learned
contents, which have been stored in TCM
memory by executing learning control,
should be initialized referring to “Learning
Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

Available O/D and 2nd coast brake rear plate
thickness
44) After applying A/T fluid to new 2nd brake gaskets (1),
install them to transaxle case (2).
45) After applying A/T fluid to reverse clutch drum thrust
bearing (1), install it to forward and reverse clutch
assembly (2).
46) Remove sealant attached to mating surface of
transaxle rear cover (1) completely.
47) Apply sealant to mating surface of transaxle rear
cover (1) by using a nozzle (2) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B) Thickness Identification mark
1.8 mm (0.071 in.) 1
2.0 mm (0.079 in.) 2
2.2 mm (0.087 in.) 3
2.4 mm (0.094 in.) 4
2.6 mm (0.102 in.) 5
I2RH0B510298-01
I2RH0B510299-01
I2RH0B510300-01
“A”2
1
I2RH0B510301-01