2006 SUZUKI SX4 Automatic

Downloaded from www.Manualslib.com manuals search engine 5A-100 Automatic Transmission/Transaxle:
Automatic Transaxle Unit Dismounting and
Remounting
S6RW0D5106029
Dismounting
1) Take down transaxle with engine. For its procedure,
refer to “Engine Assembly Removal and Installation
in Section 1D”.
2) Remove transaxle housing lower plate (1).
3) Remove drive plate to torque converter bolts (1)
engage flat head rod or the like (2) with drive plate
ring gear.4) Remove starting motor.
5) Remove bolts and nut fastening engine and
transaxle, then detach transaxle from engine.WARNING!
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
the work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.

NOTE
When detaching transaxle from engine, move
it in parallel with crankshaft and use care so
as not to apply excessive force to drive plate
and torque converter.

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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-101
Remounting
1) Make sure that torque converter is installed correctly
to transaxle.
Refer to “Automatic Transaxle Unit Assembly”.
2) Attach transaxle to engine. Tighten engine oil pan
bolts (1) to specified torque.
WARNING!
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
the work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.

Tightening torque
Engine oil pan bolt (a): 55 N·m (5.5 kgf-m, 40.0
lb-ft)
Transaxle and engine fastening bolt (b): 85 N·m
(8.5 kgf-m, 61.5 lb-ft)
Transaxle and engine fastening nut (c): 85 N·m (
8.5 kgf-m, 61.5 lb-ft)3) Tighten drive plate to torque converter bolts. Align
bolt hole of drive plate and torque converter then
tighten bolts through torque converter housing lower
plate opening.
Lock drive plate (1) by engaging flat head rod or the
like (2) with drive plate gear.
Tightening torque
Drive plate to torque converter bolt (a): 19 N·m (
1.9 kgf-m, 14.0 lb-ft)
4) Install transaxle housing lower plate (1).
Tightening torque
Transaxle housing lower plate bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
5) Install starter motor referring to “Starting Motor
Dismounting and Remounting in Section 1I”.
6) Remount engine with transaxle assembly to vehicle.
Refer to “Engine Assembly Removal and Installation
in Section 1D” for its procedure.
2, (b)
2, (b)
1, (a)
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3. Engine oil pan
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Downloaded from www.Manualslib.com manuals search engine 5A-102 Automatic Transmission/Transaxle:
Automatic Transaxle Assembly ComponentsS6RW0D5106030
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-104 Automatic Transmission/Transaxle:
Automatic Transaxle Unit DisassemblyS6RW0D5106031
CAUTION!
• Thoroughly clean transaxle exterior before
overhauling it.
• Keep working table, tools and hands clean
while overhauling.
• Use special care to handle aluminum parts
so as not to damage them.
• Do not expose removed parts to dust.
Keep them always clean.

1) Remove torque converter (1).
CAUTION!
Remove torque converter as much straight
as possible. Leaning it may cause to damage
oil seal lip.

2) Remove engine mounting LH bracket (1).
3) Remove manual select lever (1).4) Uncaulk lock washer (1), then remove lock nut (2)
and lock washer.
5) Remove transmission range sensor (1).
6) Remove output shaft speed sensor (VSS) (2) and
input shaft speed sensor (1).
7) Remove harness bracket and select cable clamp (3).
8) Remove select cable bracket (1).
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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).
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Downloaded from www.Manualslib.com manuals search engine 5A-106 Automatic Transmission/Transaxle:
16) Remove valve body harness (1).
CAUTION!
When pulling valve body harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

17) Remove governor apply No.1 gasket (1).
18) Remove cooler check valve (1) and spring (2).19) Remove accumulator pistons and springs.
To remove C2 (1), C1 (2) and B1 (3) accumulator
pistons and springs, position rag on pistons to catch
each piston. To remove pistons, force low-pressure
compressed air (1 kg/cm
2, 15 psi, 100 kPa, max) into
hole (4) as shown in figure, and pop each piston into
rag.
NOTE
Do not push accumulator pistons with
fingers or anything before removing them.
Pushing them may cause compressed fluid
in accumulator to spew out of hole and get to
your face and clothes.

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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.

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