2006 SUZUKI SX4 differential

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-143
Countershaft bearing preload
1) After applying A/T fluid to countershaft assembly (1)
and differential assembly (2), fit them.
2) Install torque converter housing to transaxle case,
then tighten bolts to specified torque.
Tightening torque
Torque converter housing bolt: 33 N·m (3.3 kgf-
m, 24.0 lb-ft)
3) Measure bearing preload (b) by using special tool.
Special tool
(A): 09928–06050
Countershaft bearing preload (b) measured as
starting torque
In the case of new bearing: 0.33 – 0.76 N⋅m (3.3 –
7.6 kg-cm, 0.24 – 0.55 lb-ft)
In the case of reused bearing: 0.17 – 0.38 N⋅m
(1.7 – 3.8 kg-cm, 0.12 – 0.28 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 countershaft bearing
preload within specification.
Available shim thickness
5) Remove differential assembly and countershaft
assembly. Countershaft bearing
preload=(b) – Differential side bearing
preload (a)
I2RH0B510257-01
I3RM0B510067-01
Thickness Identification mark
1.70 (0.066 in.) 1
1.75 (0.068 in.) 2
1.80 (0.070 in.) 3
1.85 (0.072 in.) 4
1.90 (0.074 in.) 5
1.93 (0.075 in.) 6
1.96 (0.077 in.) 7
1.99 (0.078 in.) A
2.02 (0.079 in.) B
2.05 (0.080 in.) C
2.08 (0.081 in.) D
2.11 (0.083 in.) E
2.14 (0.084 in.) F
2.17 (0.085 in.) G
2.20 (0.086 in.) H
2.25 (0.088 in.) K
2.30 (0.090 in.) L
2.35 (0.092 in.) M
2.40 (0.094 in.) N
2.45 (0.096 in.) P
2.50 (0.098 in.) Q
2.55 (0.100 in.) R
2.60 (0.102 in.) S
2.65 (0.104 in.) U
2.70 (0.106 in.) W

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-153
48) Install transaxle rear cover assembly on transaxle
case.
49) Install hook (2) to location shown in figure.
50) Tighten rear cover bolts (1).
Tightening torque
Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
51) Install fluid reservoir LH plate (1).
Tightening torque
Fluid reservoir LH plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
52) After applying A/T fluid to new governor apply No.2
gasket (1), install it to transaxle case.53) After applying A/T fluid to differential assembly (1)
and countershaft assembly (2), install them to
transaxle case.
54) After applying A/T fluid to direct clutch hub (1), install
it to planetary gear assembly.
55) After applying A/T fluid to input shaft rear thrust
bearing (1) and thrust bearing race (2), install them
into direct clutch hub (3).
56) After applying A/T fluid to input shaft front thrust
bearing (1), install it to direct clutch assembly (2).
I3RM0B510068-01
I2RH0B510303-01
I2RH0B510304-01
1
2
I4RS0A510036-01
I2RH0B510306-01
I2RH0B510307-01
I2RH0B510308-01

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 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 5B-2 Manual Transmission/Transaxle:
4WD
2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub
3. Input shaft 5th gear 8. Reverse gear shaft 13. Countershaft 5th gear 18. Countershaft 1st gear
4. Input shaft 4th gear 9. Reverse idler gear 14. Countershaft 4th gear 19. Final gear
5. High speed sleeve & hub 10. Right case 15. Countershaft 3rd gear 20. Differential case
I5RW0A520002-05
1. Input shaft 8. Reverse gear shaft 15. Countershaft 3rd gear 22. Transfer driven gear
2. 5th speed sleeve & hub 9. Reverse idler gear 16. Countershaft 2nd gear 23. Transfer bevel gear
3. Input shaft 5th gear 10. Right case 17. Low speed sleeve & hub 24. Transfer bevel pinion
4. Input shaft 4th gear 11. Countershaft 18. Countershaft 1st gear 25. Transfer right case
5. High speed sleeve & hub 12. Side cover 19. Final gear 26. Transfer left case
6. Input shaft 3rd gear 13. Countershaft 5th gear 20. Differential case 27. Transfer output flange
7. Left case 14. Countershaft 4th gear 21. Transfer intermediate shaft 28. Transfer output retainer

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

Downloaded from www.Manualslib.com manuals search engine 5B-12 Manual Transmission/Transaxle:
Manual Transaxle Unit Dismounting and
Remounting
S6RW0D5206010
Dismounting
1) Drain coolant.
2) Remove battery and tray with ECM.
3) Remove air cleaner case and resonator.
4) Remove clutch fluid pipe referring to “Clutch Fluid
Pipe Removal and Installation in Section 5C”.
5) Disconnect back up light switch coupler and undo
wiring harness clamps.
6) Disconnect gear shift and gear select control cables
(1) from transaxle.
7) Remove earth cable from transaxle.
8) Remove water inlet pipe.
9) Remove starting motor referring to “Starting Motor
Dismounting and Remounting in Section 1I”.
10) Remove transaxle to engine bolts (1) of upper side.
11) Drain transaxle oil and transfer oil, if equipped.
12) Remove engine under covers.
13) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
14) Remove exhaust No.1, No.2 and No.3 pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
15) Remove suspension frame, engine front mounting
member and engine mounting member referring to
“Front Suspension Frame, Stabilizer Bar and/or
Bushing Removal and Installation in Section 2B” and
“Engine Mountings Components in Section 1D”.16) Remove transfer referring to “Transfer Dismounting
and Remounting in Section 3C”, if equipped.
17) Remove clutch housing lower plate.
18) Support transaxle with transmission jack.
19) Remove left mounting (1) and left mounting bracket
(2).
20) Remove stiffener bolts (2), transaxle to engine bolts
(1) and nut of lower side, and then lower transaxle.
Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer
when installing it into differential gear.

Reverse dismounting procedure for remounting of
transaxle, noting the following points.
• Tighten each bolts and nuts to specified torque
referring to “Manual Transaxle Unit Components” and
“Engine Mountings Components in Section 1D”.
• Set each clamp for wiring securely.
• Fill transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change” and “Transfer Oil Change in
Section 3C”.
• Connect battery and check function of engine, clutch
and transaxle.
1
I5RW0A520011-01
1
I5RW0A520012-01
1
2
I5RW0A520013-01
1
2I5RW0A520014-01