2006 SUZUKI SX4 light

Downloaded from www.Manualslib.com manuals search engine 5A-40 Automatic Transmission/Transaxle:
Trouble Diagnosis 3
Off-vehicle repairNon operate TCC (lock-
up) systemMalfunction of TCC solenoid valveInspect. If NG, replace.
Malfunction of shift solenoid valve-A
and/or -BInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of input shaft speed sensorInspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Malfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Malfunction of engine coolant
temperature sensorInspect referring to “Engine Coolant
Temperature (ECT) Sensor Inspection in
Section 1C”. If NG, replace.
Malfunction of brake light switchInspect referring to “Brake Light Switch
Inspection in Section 9B”. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Excessive “N”
→ “D” or
“N”
→ “R” time lagMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Pressure control solenoid valve circuit
faultyInspect. If NG, replace valve body assembly.
Clogged oil strainerReplace.
Faulty valve body componentReplace valve body assembly. Condition Possible cause Correction / Reference Item
Condition Possible cause Correction / Reference Item
Unable to run in all rangeFaulty oil pumpInspect. If NG, replace.
Seized or broken planetary gearInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Damaged drive plateInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Faulty torque converterReplace.
Excessive “N”
→ “D” shift
shockFaulty forward clutchInspect. If NG, replace.
Excessive “N”
→ “R” shift
shockFaulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Poor 1
→ 2 shift,
excessive shock or
slippageFaulty 2nd brakeInspect. If NG, replace.
Faulty one-way No.1 clutchInspect. If NG, replace.
Poor 2
→ 3 shift,
excessive shock or
slippageFaulty direct clutchInspect. If NG, replace.
Poor 3
↔ O/D shift,
excessive shock or
slippageFaulty forward clutchInspect. If NG, replace.
Faulty O/D and 2nd coast brakeInspect. If NG, replace.
Poor 3
→ 2 shift,
excessive shock or
slippageFaulty direct clutchInspect. If NG, replace.
Faulty one-way No.1 clutchInspect. If NG, replace.
Poor 2
→ 1 shift,
excessive shock or
slippageFaulty 2nd brakeInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-41
Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ON (Non-Euro-
OBD Model)
S6RW0D5104054
Troubleshooting
Transmission Warning Light Circuit Check – Light Does Not Come “ON” at Ignition Switch ON (Non-
Euro-OBD Model)
S6RW0D5104055
TroubleshootingNon operate TCC (lock-
up) systemFaulty torque converterReplace.
Excessive “N”
→ “D” time
lagFaulty oil pumpInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
Excessive “N”
→ “R” time
lagFaulty oil pumpInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.
Poor engine brake in
downshift to “2” rangeFaulty O/D and 2nd coast brakeInspect. If NG, replace.
Poor engine brake in
downshift to “L” rangeFaulty 1st and reverse brakeInspect. If NG, replace. Condition Possible cause Correction / Reference Item
Step Action Yes No
1Diagnostic Trouble Code (DTC) Check
1) Check DTC referring to “DTC Check”.
Is there any DTC(s)?Perform DTC Flow to
repair and retry.Substitute a known-
good TCM and recheck.
If OK, substitute a
known-good
combination meter and
recheck.
Step Action Yes No
1Combination Meter Power Supply Check
1) Turn ignition switch ON.
Does other indicator / warning lights in combination meter
comes ON?Go to Step 2. Repair combination
meter power supply
circuit referring to
“Combination Meter
Circuit Diagram in
Section 9C”.
2 1) TCM power and ground circuit check referring to “TCM
Power and Ground Circuit Check”.
Is it in good condition?Go to Step 3. Repair or replace.
3DTC check
1) Check DTC referring to “DTC Check”.
Is there DTC U0073 or U0100?Go to applicable DTC
diag. flow.Go to Step 4.
4Combination Meter Function Check
1) Turn ignition switch ON.
Does A/T selector position indicator show correct select
lever position?Replace combination
meter.Substitute a known-
good TCM and recheck.

Downloaded from www.Manualslib.com manuals search engine 5A-90 Automatic Transmission/Transaxle:
3) Check that engine starts in “N” and “P” ranges but it
doesn’t start in “D”, “2”, “L” or “R” range. Also, check
that back-up lamp lights in “R” range.
If faulty condition cannot be corrected by adjustment,
disconnect transmission range sensor connector
and check that continuity exists as shown by moving
manual select lever.
Output Shaft Speed Sensor (VSS) Removal and
Installation
S6RW0D5106010
Removal
1) Disconnect negative cable at battery.
2) Disconnect output shaft speed sensor connector (2).
3) Remove output shaft speed sensor (VSS) (1) by
removing its bolt.
Installation
1) Apply A/T fluid to output shaft speed sensor O-ring.
2) Install output shaft speed sensor (VSS) (1) to A/T
case and tighten bolt to specified torque.
Tightening torque
Output shaft speed sensor (VSS) bolt (a): 13
N·m (1.3 kgf-m, 9.5 lb-ft)3) Connect output shaft speed sensor connector (2) to
output shaft speed sensor (VSS) (1).
4) Connect negative cable to battery.
Output Shaft Speed Sensor (VSS) InspectionS6RW0D5106011
1) Connect positive cable of 12 volt battery to “A”
terminal of sensor and ground cable to “C” terminal.
Then using voltmeter, check voltage between “B”
terminal and “C” terminal with output shaft speed
sensor (VSS) driven gear rotated.
If measured voltage (pulse signal) is not as
specified, replace sensor.
Output shaft speed sensor (VSS) output voltage
Pulse signal of alternating 0 – 1 V and 10 – 14 V
2) Check output shaft speed sensor (VSS) driven gear
(1) for wear.
Replace if necessary.
1 2
3
4
5
9
87
6
1
P
R
N
D
2
LTerminal No.
Sensor Position
23456789
I3RH0A510038-01
12I5RW0C510032-01
(a)
12
I5RW0C510033-01
I2RH0B510045-01
I2RH0B510046-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-93
7) Remove oil strainer assembly (3).
8) Remove transmission fluid temperature sensor (1)
from sensor clamp.
9) Disconnect solenoid connectors (2).
10) Remove shift solenoid valve-A (No.1) (1), shift
solenoid valve-B (No.2) (2) and timing solenoid valve
(3) by removing bolts.Installation
1) Install shift solenoid valve-A (No.1) (1), shift solenoid
valve-B (No.2) (2) and timing solenoid valve (3).
Tightening torque
Shift solenoid bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-
ft)
2) Connect solenoid connectors identifying their
installing positions by wire color.
3) Install transmission fluid sensor (6) and sensor wire
to clamp.
I2RH0B510054-01
2
1
I5RW0C510038-02
12
3
I4RS0A510028-01
Solenoid coupler Wire color
Shift solenoid valve-A (No.1) (2) White
Shift solenoid valve-B (No.2) (3) Black
Timing solenoid valve (1) Yellow
TCC pressure control solenoid
valve (4)Light green / Brown
Pressure control solenoid valve
(5)Green / Gray
12
3 (a)
I4RS0A510029-01
2 4
6
1
3
5
I5RW0C510039-02

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-105
9) Remove fluid cooler pipes (1) and pipe unions (2).
10) Remove fluid level gauge (3) and fluid filler tube (4).
11) Remove oil pan (1) and oil pan gasket (2).
NOTE
• For removal of oil pan, do not turn
transaxle over as this will contaminate
valve body with foreign materials in
bottom of oil pan.
• When removing oil pan, tap around it
lightly with plastic hammer. Do not force it
off by using screwdriver or the like.

12) Remove oil strainer assembly (1).13) Disconnect connectors (2) from solenoid valves and
transmission fluid temperature sensor (1).
14) Remove valve body assembly bolts.
CAUTION!
Be careful not to let manual valve fall off
when removing valve body assembly.

NOTE
There are five kinds of bolts (bolts A (1), B (2),
C (3), D (4) and E (5)) fixing valve body
assembly.

15) Remove manual valve rod (1) from manual valve
lever (2), then remove valve body assembly (3).
43
12
I5RW0C510060-01
I2RH0B510086-01
I2RH0B510087-01
2
1
I5RW0C510038-02
I2RH0B510089-01
I2RH0B510090-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-107
20) Remove transaxle case plug (1).
21) Remove torque converter housing bolts.
22) Remove torque converter housing (1) while tapping
around it lightly with plastic hammer.
23) Remove breather hose (1).
24) Remove breather union (2).
25) Measure input shaft thrust play.
Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
When input shaft thrust play is out of specification,
select input shaft front thrust bearing with proper
thickness from among the list below and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
Available input shaft front thrust bearing
thickness
“a”: 0.8, 1.4 mm (0.032, 0.055 in.)26) Remove oil pump assembly (1).
27) Remove direct clutch assembly (1).
28) Remove input shaft front thrust bearing (1).
NOTE
If input shaft front thrust bearing is not
found, it may have been taken out with oil
pump assembly.

I2RH0B510095-01
I3RM0B510060-01
1
2
I2RH0B510097-01
I2RH0B510098-01
I2RH0B510099-01
I2RH0B510100-01
I2RH0B510101-01

Downloaded from www.Manualslib.com manuals search engine 5A-122 Automatic Transmission/Transaxle:
Direct Clutch Assembly InspectionS6RW0D5106038
Clutch Discs, Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated, discolored,
replace all discs.
• Before assembling new discs, soak them
in A/T fluid for at least two hours.

Direct Clutch Return Spring Subassembly
Measure free length of direct clutch return spring
subassembly.
Direct clutch return spring subassembly free length
“a”: 36.04 mm (1.419 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Direct Clutch Piston
Shake direct clutch piston lightly and check that check
ball (1) is not stuck.
Blow in low pressure air (Max. 100 kPa, 1 kg/cm
2, 15 psi)
to check ball to check that there is no leakage.
I2RH0B510172-01
I2RH0B510173-01
I2RH0B510174-01

Downloaded from www.Manualslib.com manuals search engine 5A-146 Automatic Transmission/Transaxle:
12) Install 1st and reverse brake plate snap ring so that
its both ends would be positioned in correct locations
as shown in figure.
13) Using special tools, measure 1st and reverse brake
piston stroke when compressed air (400 – 800 kPa,
4 – 8 kg/cm
2, 57 – 113 psi) is brown through oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.791 – 1.489 mm (0.0311 – 0.0586 in.)14) Install reduction drive gear (1) to transaxle case (3)
by using special tools and hydraulic press.
CAUTION!
• Do not use transaxle case as groundwork
to press fit reduction drive gear.
• Do not give load more than 20 kN (2000 kg,
4410 lb) with hydraulic press. Otherwise, it
may result in damaging reduction drive
gear bearing.

NOTE
When replacing reduction drive gear, replace
it together with reduction driven gear as a
set.

Special tool
(A): 09951–18210
(B): 09944–78210
15) Install parking lock pawl (1) and spring (2). Apply A/T
fluid to parking lock pawl shaft, then insert it into
transaxle case.
[A]: Correct [B]: Incorrect
I2RH0B510268-01
I2RH0B510269-01
2. Stand that can slightly lift transaxle case.
I2RH0B510270-01
I2RH0B510271-01