2006 SUZUKI SX4 clutch

Downloaded from www.Manualslib.com manuals search engine 5B-20 Manual Transmission/Transaxle:
2) Remove bearing set shim.
3) Remove snap ring (1) using special tool.
Special tool
(A): 09900–06107
4) Remove gear shift locating bolts (1), then take out
locating springs and steel balls.
5) Remove reverse shaft bolt (2) with washer.
6) Remove transaxle case bolts (1) from outside and
another bolts from clutch housing side.
7) Tapping left case flanges with plastic hammer,
remove left case.8) Pull out reverse gear shaft (1) with washer (2), then
take off reverse idler gear (3).
9) Remove reverse gear shift lever bolts (4) and
reverse gear shift lever (5).
10) Pull out 5th & reverse gear shift guide shaft (6)
together with 5th & reverse gear shift shaft (7).
NOTE
When removing 5th & reverse gear shift shaft
(7) and guide shaft (6), push up high speed
gear shift shaft and shift it to 4th to facilitate
removal of 5th & reverse shift shaft.

11) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, then take out
input shaft assembly (1), countershaft assembly (2),
high speed gear shift shaft (3) and low speed gear
shift shaft (4) all at once.
12) Remove countershaft left bearing outer race from left
case.
13) Remove differential assembly from right case.
2. Input shaft
3. Input shaft left bearing
1 (A)
2
3
I4RH01520019-01
1I5RW0A520021-01
I4RH01520020-01
I3RH0A520012-01
I2RH01520035-01

Downloaded from www.Manualslib.com manuals search engine 5B-22 Manual Transmission/Transaxle:
6) Clean mating surfaces of both right and left cases,
apply sealant to left case (2) as shown in the figure
by such amount that its section is 1.5 mm (0.059 in.)
in diameter then mate it with right case (1).
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
7) Tighten case bolts (3) from outside and tighten
another case bolts from clutch housing side to
specified torque.
Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
8) Install reverse shaft bolt (4) to which thread lock
cement has been applied, with aluminum washer
and tighten it to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Reverse shaft bolt (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft)9) Check locating springs (2, 4 and 5) for deterioration
and replace with new ones as necessary.
Locating spring
10) Install steel balls (3) and locating springs (2, 4 and 5)
for respective gear shift shaft and tighten bolts (1) to
which thread lock cement has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Gear shift locating bolt (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
11) Install new snap ring (1) using special tool.
Special tool
(A): 09900–06107
I5RW0A520023-01
Locating spring free length Standard Service limit
Low speed (2)53.1 mm
(2.091 in.)47.8 mm
(1.881 in.)
High speed (4)45.9 mm
(1.807 in.)41.4 mm
(1.629 in.)
5th & reverse (5)29.9 mm
(1.777 in.)27.0 mm
(1.062 in.)
2. Input shaft
3. Input shaft left bearing
1, (a), “A”
2
3
4
5
I5RW0A520024-02
1 (A)
2
3
I3RH0A520016-01

Downloaded from www.Manualslib.com manuals search engine 5C-1 Clutch:
Transmission / Transaxle
Clutch
General Description
Clutch (Hydraulic Type) ConstructionS6RW0D5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.
I5RW0A530001-01
1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly
2. Flywheel 5. Clutch cover 8. Input shaft bearing
3. Clutch disc 6. Diaphragm spring 9. Input shaft

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-2
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS6RW0D5304001
Condition Possible cause Correction / Reference Item
SlippingImproper clutch pedal free travelBleed air or replace master cylinder.
Worn or oily clutch disc facingReplace disc.
Warped disc, pressure plate or flywheel
surfaceReplace disc, clutch cover or flywheel.
Weakened diaphragm springReplace clutch cover.
Master cylinder piston or seal cup not
returningReplace master cylinder.
Dragging clutchImproper clutch pedal free travelBleed air or replace master cylinder.
Weakened diaphragm spring, or worn
spring tipReplace clutch cover.
Rusted input shaft splinesLubricate.
Damaged or worn splines of transaxle
input shaftReplace input shaft.
Excessively wobbly clutch discReplace disc.
Clutch facings broken or dirty with oilReplace disc.
Fluid leakageRepair or replace.
Clutch vibrationGlazed (glass-like) clutch facingsRepair or replace disc.
Clutch facings dirty with oilReplace disc.
Release bearing slides unsmoothlyReplace clutch operating cylinder assembly.
Wobbly clutch disc, or poor facing
contactReplace disc.
Weakened torsion springs in clutch discReplace disc.
Clutch disc rivets looseReplace disc.
Distorted pressure plate or flywheel
surfaceReplace clutch cover or flywheel.
Weakened engine mountingReplace engine mounting.
Loosened engine mounting bolt or nutRetighten engine mounting bolt or nut.
Noisy clutchWorn or broken release bearingReplace clutch operating cylinder assembly.
Input shaft front bearing worn downReplace input shaft bearing.
Excessive rattle of clutch disc hubReplace disc.
Cracked clutch discReplace disc.
Pressure plate and diaphragm spring
rattlingReplace clutch cover.
Grabbing clutchClutch disc facings soaked with oilReplace disc.
Clutch disc facings excessively wornReplace disc.
Rivet heads showing out of facingReplace disc.
Weakened torsion springsReplace disc.

Downloaded from www.Manualslib.com manuals search engine 5C-3 Clutch:
Repair Instructions
Clutch Pedal InspectionS6RW0D5306001
Cylinder Push Rod Play “a”
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).
Clutch Pedal Free Travel “b”
1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel
“b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.
Clutch Release Margin “c”
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
Clutch release margin
“c”: 25 – 55 mm (0.98 – 2.17 in.)6) If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”.Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS6RW0D5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to the reservoir cap of the brake master
cylinder.
Air Bleeding of Clutch SystemS6RW0D5306003
CAUTION!
When operating the pedal stroke for air
bleeding of clutch system, after releasing the
clutch pedal, be sure to wait 1 second or
more before depressing it again. Otherwise,
the oil seal of operating cylinder will be
damaged, resulting in oil leakage.

Bleed air from clutch system.
Refer to “Air Bleeding of Brake System in Section 4A”.
I5RW0A530002-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-4
Clutch Fluid Pipe and Hose LocationS6RW0D5306004
Clutch Fluid Pipe Removal and InstallationS6RW0D5306005
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2).Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted
surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS6RW0D5306006
Check pipe (1) for damage, dirt and leak. Replace if
check result is not satisfactory.
4 [A]
3131
22
4
I5RW0A530003-02
[A]: RH steering vehicle 3. Clutch reservoir hose
1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
2
6
5 74
3
1
2
I5RW0B530002-03
[A]: LH steering vehicle
[B]: RH steering vehicle
I5RW0A530005-01

Downloaded from www.Manualslib.com manuals search engine 5C-5 Clutch:
Clutch Master Cylinder Removal and
Installation
S6RW0D5306007
Removal
1) Clean around brake master cylinder reservoir cap
and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe (4) from clutch master
cylinder (1) referring to “Clutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal, and then
remove clutch master cylinder.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch master cylinder nut to specified torque.
Tightening torque
Clutch master cylinder nut: 13 N·m (1.3 kgf-m, 9.5
lb-ft)
Clutch Operating Cylinder Assembly Removal
and Installation
S6RW0D5306008
CAUTION!
• Do not allow fluid to get on painted
surfaces. It may cause painted surface
damage.
• Do not disassemble clutch operating
cylinder assembly.

Removal
1) Clean around reservoir cap of brake master cylinder
and take out fluid with syringe or such.
2) Dismount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
3) Loosen clutch fluid pipe flare nut (1) of clutch
operating cylinder assembly (2).
4) Remove clutch pipe joint sleeve (3) from transaxle
and then remove clutch fluid pipe (4).
5) Remove clutch operating cylinder assembly from
transaxle.
3. Brake booster
1
3
2
4
I5RW0A530006-01
“A”
I5RW0A530007-01
3
4
2
1
I5RW0A530008-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-6
Installation
1) Install clutch operating cylinder assembly (2) to
transaxle. Tighten new mounting bolts to specified
torque.
Tightening torque
Clutch operating cylinder assembly mounting
bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect clutch fluid pipe (4) to clutch operating
cylinder assembly temporarily.
3) Install clutch pipe joint sleeve (3) to transaxle
securely and then tighten clutch fluid pipe flare nut
(1) to specified torque.
Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)4) Remount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
5) Bleed air from system and check clutch pedal free
travel. Refer to “Air Bleeding of Clutch System” and
“Clutch Pedal Inspection”.
Clutch Operating Cylinder Assembly InspectionS6RW0D5306013
Check clutch fluid leakage, spring for damage and
bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.
Clutch Cover, Clutch Disc and Flywheel ComponentsS6RW0D5306010
3
4
(a)
2
1, (b)
I5RW0A530009-01
I5RW0B530005-03
2
1
3(a)
6
4
5
(b)
I6RW0C530001-01
1. Clutch cover 4. Flywheel : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Clutch disc 5. Input shaft bearing : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
3. Clutch cover bolt 6. Flywheel bolt : Do not reuse.