2006 SUZUKI SX4 Automatic

Downloaded from www.Manualslib.com manuals search engine 5A-108 Automatic Transmission/Transaxle:
29) Remove input shaft rear thrust bearing (1) and thrust
bearing race (2).
NOTE
If input shaft rear thrust bearing is not found,
it may have been taken out with direct clutch
assembly.

30) Remove direct clutch hub (1).
31) Remove differential assembly (1) and countershaft
assembly (2).32) Remove governor apply No.2 gasket (1).
33) Remove fluid reservoir LH plate (1).
34) Turn over transaxle and remove rear cover assembly
(1).
35) Remove reverse clutch drum thrust bearing (1).
NOTE
If reverse clutch drum thrust bearing is not
found, it may have been taken out with rear
cover assembly.

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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.

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Downloaded from www.Manualslib.com manuals search engine 5A-110 Automatic Transmission/Transaxle:
40) Remove O/D and 2nd coast brake rear plate (1),
discs (2), separator plate (3) and retaining plate (4).
41) Remove forward clutch hub (1).
42) Remove rear sun gear thrust bearing (1) from
forward clutch hub (2).
NOTE
If rear sun gear thrust bearing is not found on
forward clutch hub, it may have been left in
transaxle.

43) Remove rear sun gear thrust bearing race (1).44) Remove rear planetary sun gear subassembly (1)
and one-way clutch No.1 assembly (2).
45) Remove planetary gear thrust bearing (1).
NOTE
If planetary gear thrust bearing is not found
on one-way clutch No.1 assembly, it may
have been left in transaxle.

46) Remove one-way clutch No.1 assembly (2) from rear
planetary sun gear subassembly (3).
47) Remove planetary carrier thrust washer (1).
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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
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Downloaded from www.Manualslib.com manuals search engine 5A-112 Automatic Transmission/Transaxle:
53) Remove 2nd brake piston assembly (1).
54) Remove 2nd brake return spring subassembly (2).
55) Remove 2nd brake separator plates (1), discs (2)
and retaining plate (3).
56) Remove brake drum gasket (1).
57) Remove one-way clutch outer race retainer (1).58) Check one-way clutch No.2 as follows.
• Ensure planetary carrier (1) rotates only in
counterclockwise direction “A”, never in clockwise
direction “B”.
• If the planetary carrier rotates both ways or does
not rotate either way, one-way clutch No.2
assembly will need to be replaced with new one-
way clutch No.2 assembly.
59) Remove one-way clutch No.2 assembly (1).
60) Remove planetary gear assembly (1).
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-113
61) Measure 1st and reverse brake piston stroke.
If piston stroke exceeds specified value,
disassemble, inspect and replace discs and plates.
• Using special tool, measure 1st and reserve brake
piston stroke when compressed air (400 – 800
kPa, 4 – 8 kg/cm
2, 57 – 113 psi) is blown through
oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.79 – 1.49 mm (0.031 – 0.059 in.)
62) Remove snap ring while the 1st and reverse brake
piston return springs are compressed using special
tool and hydraulic press.
CAUTION!
Do not press 1st and reverse brake return
spring subassembly in over 0.8 mm (0.031
in.).
Excessive compression may cause damage
to return spring subassembly, discs, plates
and/or piston.

Special tool
(A): 09926–9762063) Remove 1st and reverse brake retaining plate, discs
and separator plates.
64) Remove 1st and reverse brake return spring
subassembly (1).
65) Turn over transaxle and uncaulk reduction drive gear
nut (1).
66) Secure reduction drive gear (1) with parking lock
pawl, then remove reduction drive gear nut.
CAUTION!
• It is recommended that this operation
should be carried out on rubber mat to
prevent damaging transaxle case.
• Never reuse removed nut.

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Downloaded from www.Manualslib.com manuals search engine 5A-114 Automatic Transmission/Transaxle:
67) Using special tools and hydraulic press, remove
planetary ring gear subassembly (1).
CAUTION!
Do not reuse planetary ring gear
subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.

Special tool
(A): 09913–84510
(B): 09923–78210
68) Remove parking lock pawl shaft, then spring (2) and
parking lock pawl (1).69) Screwing 3 bolts (1), remove reduction drive gear
(2).
CAUTION!
Screw 3 bolts into reduction drive gear
uniformly, or reduction drive gear, bearing
and transaxle case may be damaged.

Bolt length
30 mm (1.20 in.)
70) Blowing compressed air from oil hole (1) of oil pump,
remove 1st and reverse brake piston (2).
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-115
71) Remove parking lock pawl bracket (1).
72) With slotted screwdriver, cut and unfold manual
valve lever spacer (1) and proceed to remove
manual valve lever spacer.
73) Using spring pin remover with 3 mm (0.12 in.) in
diameter and hammer, drive out manual valve lever
pin (1).
74) Remove manual shift shaft (2).75) Remove parking lock pawl rod (2) from manual valve
lever (1).
76) Remove manual detent spring (1).
77) Remove manual shift shaft oil seal (1).
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