2006 SUZUKI SX4 tcm

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-109
36) Remove 2nd brake gasket (1).
37) Measure O/D and 2nd coast brake piston stroke.
If piston stroke exceeds specification, inspect and
replace plates and discs.
• Measure dimension “a” from mating surface 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.)
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.

38) Remove forward and reverse clutch assembly (1).
39) Remove intermediate shaft thrust bearing front race
(1), thrust bearing (2) and rear race (3) from forward
and reverse clutch assembly (4).
NOTE
If intermediate shaft thrust bearing and/or
races are not found on forward and reverse
clutch assembly, they may have been left in
transaxle.

I2RH0B510109-01
I2RH0B510110-01
I2RH0B510111-01
I2RH0B510112-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-111
48) Remove O/D and 2nd coast brake retaining plate
snap ring (1).
49) Remove front planetary sun gear (1).
50) Remove front sun gear thrust bearing race (2) from
front planetary sun gear (1).
51) Before disassembling 2nd brake piston assembly
(4), 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 brake 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
“a”: 0.40 – 1.25 mm (0.016 – 0.049 in.)
52) Using special tool and hydraulic press, remove 2nd
brake piston snap ring (1).
CAUTION!
Do not press 2nd brake piston assembly in
over 0.4 mm (0.016 in.).
Excessive compression may cause damage
to piston assembly, return spring, plates and/
or discs.

Special tool
(A): 09926–96050
I2RH0B510120-01
I2RH0B510121-01
I2RH0B510122-01
3
4 1 2
“a”4
I2RH0B510123-01
I2RH0B510124-01

Downloaded from www.Manualslib.com manuals search engine 5A-120 Automatic Transmission/Transaxle:
Direct Clutch Assembly Disassembly and
Reassembly
S6RW0D5106037
CAUTION!
When clutch disc, retaining plate and/or
separator plate of direct clutch 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.

Disassembly
1) Remove plate snap ring (1) then remove direct
clutch retaining plate, discs and separator plates.
2) Using special tool and hydraulic press, remove shaft
snap ring (1).
Special tool
(A): 09926–98310
CAUTION!
Do not press direct clutch return spring
subassembly in over 0.7 mm (0.027 in.).
Excessive compression may cause damage
to direct clutch return spring subassembly
and/or piston.

3) Remove direct clutch return spring assembly (2).4) Using a finger to block oil hole (1), apply
compressed air (400 – 800 kPa, 4 – 8 kg/cm
2, 57 –
113 psi) to opposite hole, which will assist in removal
of the clutch piston.
5) Remove outer O-ring (1).
6) Remove inner O-ring (2).
7) Remove input shaft seal rings (1).
I2RH0B510162-01
I2RH0B510163-01
2. Direct clutch piston
1. Input shaft subassembly
I2RH0B510164-01
I2RH0B510165-01
I2RH0B510166-01
I2RH0B510167-01

Downloaded from www.Manualslib.com manuals search engine 5A-124 Automatic Transmission/Transaxle:
2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm2,
57 – 113 psi) through oil hole (1) of transaxle rear
cover with the special tool attached on the upper
surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
If piston stroke exceeds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Forward and Reverse Clutch Assembly
Disassembly and Reassembly
S6RW0D5106041
CAUTION!
When clutch disc, retaining plate and/or
separator plate of forward clutch 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.

Disassembly
1) Remove reverse clutch plate snap ring (1) and take
out reverse clutch retaining plate, discs, separator
plates and clutch cushion plate from intermediate
shaft subassembly.2) Remove forward clutch plate snap ring (1) and take
out forward clutch retaining plate, discs and
separator plates from forward clutch drum.
3) Remove balancer snap ring by using special tool and
hydraulic press.
Special tool
(A): 09926–97610
CAUTION!
Do not press forward clutch return spring
subassembly in over 1.5 mm (0.059 in.).
Excessive compression may cause damage
to return spring subassembly and/or
balancer.

4) Remove forward clutch balancer (1).
5) Remove forward clutch return spring subassembly
(1).
I2RH0B510177-02
I2RH0B510178-01
2. Intermediate shaft subassembly
I2RH0B510179-01
I2RH0B510180-01
I2RH0B510181-01

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-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

Downloaded from www.Manualslib.com manuals search engine 6C-4 Power Assisted Steering System:
Schematic and Routing Diagram
EPS System Wiring Circuit DiagramS6RW0D6302001
[A]
123
45
3 21
4
567
8
9 11
10 12 13
141516
17 18 19201
2
[B]
1
2
[C] [D]
10 9 8 7654 3 21
16 15 14 13 12 11
26 25 24 2322 21 20 19 18 17
32 31 30 29 28 27
[F][E]
12
BRN RED/
BLU GRY LT GRN/
BLK
BLK
RED
WHT GRN
BLK
E11-1
E11-5
E11-14
E11-12
[J]:E01-44E01-4
[J]:E01-27E01-26
E12-1
E12-2
E11-10E11-8
E11-9
E11-19
E13-1 GRN
GRY
GRN
WHT
G241-25G241-31
RED/BLK
11
12
1314 3 18
20
21
7 19
4 12
22
12V
E13-2BLK
9V
REDE11-20
12V
12V
E61-2
E61-1
610
55
5V
8
E11-115V
PPL
E11-4
9
23
+BB
BLU/
WHTE04-9
1524YELE11-18E31-5
E31-2
E31-39V
3V
E31-4
E31-1IG11617
C07-25
[H]
[G]
G04-15
[I]:G04-22
25L313-3
[I]
I6RW0D630001-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 3. Junction block assembly 15. BCM
[B]: P/S control module connector No.2 “E13” (viewed from harness side) 4. Main fuse 16. Output shaft speed sensor
[C]: P/S control module connector No.3 “E12” (viewed from harness side) 5. Front (left/right) wheel speed sensor 17. TCM
[D]: Combination meter connector “G241” (viewed from harness side) 6. ABS control module 18. Individual circuit fuse box No.1
[E]: Torque sensor connector “E31” (viewed from harness side) 7. Combination meter 19. “IGN” fuse
[F]: Motor connector “E61” (viewed from harness side) 8. “EPS” warning light 20. “P/S” fuse
[G]: M/T model 9. Data link connector (DLC) 21. “IG1 SIG” fuse
[H]: A/T model 10. ECM 22. “MTR” fuse
[I]: Junction block without BCM model (Taiwan model) 11. P/S control module 23. To ABS control module
[J]: M15A engine with 4A/T equipped with slip control model (Hong Kong
model)12. P/S motor 24. To HVAC control module
1. Main fuse box 13. Shield 25. To SDM
2. Ignition switch 14. Torque sensor (built into steering gear case)

Downloaded from www.Manualslib.com manuals search engine 6C-10 Power Assisted Steering System:
)
C1121No vehicle speed signal
(60 Seconds or More)Vehicle speed signal is 0 km/h
even though engine speed is
more than 4000 rpm for more
than 60 seconds continuously
(before elapse of 5 min from
engine start)
or
vehicle speed signal is 0 km/h
even though engine speed is
more than 2500 rpm for more
than 60 seconds continuously
(after elapse of 5 min for engine
start).• Vehicle speed signal
circuit
•BCM
•ECM
• TCM (A/T model)
• ABS control module (M/
T model)
• P/S control module
• CAN communication
line circuit1 driving
cycleDoes not
light up
)
C1122Engine speed signalEngine speed signal is less than
220 rpm for more than 0.8
seconds.
or
Engine speed signal is less than
220 rpm for more than 20
seconds continuously even
though vehicle speed signal is
more than 50 km/h.• Engine speed signal
circuit
•ECM
• P/S control module1 driving
cycle1 driving
cycle
)
C1123No vehicle speed signal
(30 seconds or more)Vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though
engine speed is more than 4000
rpm for more than 30 seconds
continuously (before elapse of 5
min from engine start)
or
vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though
engine speed is more than 2500
rpm for more than 30 seconds
continuously (after elapse of 5
min for engine start).• Vehicle speed signal
circuit
•BCM
•ECM
• TCM (A/T model)
• ABS control module (M/
T model)
• P/S control module
• CAN communication
line circuit3 driving
cycle3 driving
cycle
)
C1124Vehicle speed
performance
(impossible
deceleration) Vehicle speed signal is less than
5 km/h for more than 5 seconds
continuously with more than
specified deceleration speed (–
20 m/s
2) from over 20 km/h.1 driving
cycleDoes not
light up DTC No. Detecting itemDetecting condition
(DTC will set when detecting)Trouble area DTC“EPS”
warning
light