2006 SUZUKI SX4 Automatic

Downloaded from www.Manualslib.com manuals search engine 5A-116 Automatic Transmission/Transaxle:
Oil Pump Assembly ComponentsS6RW0D5106032
Oil Pump Assembly Disassembly and
Reassembly
S6RW0D5106033
Disassembly
1) Remove O-ring from pump body.
2) Remove 8 oil pump subassembly bolts (1) and stator
shaft assembly (2).3) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
I5RW0C510061-01
1. Oil seal
: Apply grease 99000-25030 to oil seal lip.5. Oil pump drive gear : Apply automatic transaxle fluid.
2. O-ring 6. Stator shaft assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
3. Oil pump body 7. Oil pump subassembly bolts : Do not reuse.
4. Oil pump driven gear
2
1
I4RS0A510041-01
2. Oil pump body
I2RH0B510150-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-117
Reassembly
1) Install new oil pump body oil seal (1).
Use special tool and hammer to install it, and then
apply grease to its lip portion.
Special tool
(A): 09913–85210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
2) Install driven gear and drive gear to oil pump body
after applying A/T fluid.
3) Install stator shaft assembly to oil pump body and
tighten 8 pump subassembly bolts (1) to
specification.
Tightening torque
Oil pump subassembly bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
4) After applying A/T fluid to new O-ring, install it to oil
pump body.
5) Check drive gear for smooth rotation by using torque
converter (1).Oil Pump Assembly InspectionS6RW0D5106034
1) Check body clearance of driven gear (1).
Push driven gear to one side of oil pump body (2).
Using a feeler gauge, measure clearance between
driven gear and body. If clearance exceeds its
standard value, replace oil pump assembly.
Clearance between oil pump driven gear and oil
pump body
Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.)
2) Check tip clearance of both drive and driven gears.
Using a feeler gauge, measure clearance between
drive and driven gear tips. If clearance exceeds its
standard value, replace oil pump assembly.
Tip clearance between oil pump drive gear and
oil pump driven gear
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
2. Oil pump body
I2RH0B510151-01
1, (a)
I4RS0A510042-01
1
I4RS0A510043-01
I2RH0B510154-01
I2RH0B510155-01

Downloaded from www.Manualslib.com manuals search engine 5A-118 Automatic Transmission/Transaxle:
3) Check side clearance of both gears.
Using a straightedge (1) and a feeler gauge (2),
measure side clearance between gears and pump
body.
If clearance exceeds its standard value, replace oil
pump assembly.
Side clearance between gears and oil pump body
Standard: 0.02 – 0.05 mm (0.0008 – 0.0019 in.)
4) Using special tool, measure stator shaft bush (1)
bore.
If measured stator shaft bush bore is out of
specifications, replace oil pump assembly with new
one.
Special tool
(A): 09900–20605
Stator shaft bush bore
Standard: 18.424 – 18.450 mm (0.7254 – 0.7264
in.)5) Install direct clutch assembly (1) to stator shaft
assembly (2), then ensure that direct clutch
assembly turns smoothly.
If unsmooth rotation or noise are found in oil pump
assembly, replace oil pump assembly with new one.
This check should also be done to input shaft
assembly and replace input shaft assembly if
necessary.
6) Using special tool, measure oil pump body bush
bore.
If measured oil pump body bush (1) bore is out of
specifications, replace oil pump assembly with new
one. Torque converter also needs to be checked.
Replace torque converter, if necessary.
Special tool
(A): 09900–20605
Oil pump body bush bore
Standard: 38.113 – 38.138 mm (1.5005 – 1.5015
in.)
I2RH0B510156-01
I2RH0B510157-01
I2RH0B510158-01
I2RH0B510159-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-119
Direct Clutch Assembly ComponentsS6RW0D5106035
Direct Clutch Assembly Preliminary CheckS6RW0D5106036
Install direct clutch assembly (1) to oil pump assembly
(2) blow in air (400 – 800 kPa, 4 – 8 kg/cm2, 57 – 113
psi) through oil hole (3) of oil pump assembly with
special tool attached on upper surface of direct clutch
piston, and measure piston stroke of direct clutch.
If piston stroke exceeds specified value, disassemble,
inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
I2RH0B510160-01
1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate
2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring
3. Input shaft subassembly 8. Shaft snap ring : Apply automatic transaxle fluid.
4. Inner O-ring 9. Direct clutch separator plate : Do not reuse.
5. Direct clutch piston 10. Direct clutch disc
I2RH0B510161-01

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 Automatic Transmission/Transaxle: 5A-121
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal ring and O-ring. Apply A/T fluid before
installation.
• Do not damage direct clutch return spring
subassembly (1) and piston by pressing in direct
clutch return spring subassembly passing through its
original installing position over 0.7 mm (0.027 in.).
Special tool
(A): 09926–98310
• Apply A/T fluid to direct clutch separator plates (4),
discs (3) and retaining plate (2).
• Install direct clutch separator plates (4), discs (3),
retaining plate (2) and snap ring (1) to input shaft
subassembly.
• Install plate snap ring so that its both ends would be
positioned in correct locations as shown in figure.• After assembly, measure direct clutch piston stroke.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
When piston stroke is out of specification, select direct
clutch retaining plate with suitable thickness from
among the following table and replace it.
Available direct clutch retaining plate thickness
I2RH0B510168-01
I2RH0B510169-01
[A]: Correct [B]: Incorrect
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
2.8 mm (0.110 in.) 4
1. Direct clutch assembly 3. Oil hole
2. Oil pump assembly
I2RH0B510170-01
I2RH0B510171-01

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 Automatic Transmission/Transaxle: 5A-123
Forward and Reverse Clutch Assembly ComponentsS6RW0D5106039
Forward and Reverse Clutch Assembly
Preliminary Check
S6RW0D5106040
1) Install forward and reverse clutch assembly (1) to
transaxle rear cover (2), blow in compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) through oil
hole (4) of transaxle rear cover with the special tool
attached on the upper surface of reverse clutch
retaining plate (3), and measure reverse clutch
piston stroke.
If piston stroke exceeds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
I3RM0B510061-01
1. Forward clutch balancer 8. Intermediate shaft seal ring 15. Forward clutch retaining plate
2. Forward clutch return spring subassembly 9. Reverse clutch plate snap ring 16. Forward clutch disc
3. Forward clutch piston 10. Reverse clutch retaining plate 17. Forward clutch separator plate
4. Forward clutch piston O-ring 11. Reverse clutch separator plate 18. Balancer snap ring
5. Forward clutch drum 12. Reverse clutch disc : Apply automatic transaxle fluid.
6. Forward clutch drum O-ring 13. Reverse clutch cushion plate : Do not reuse.
7. Intermediate shaft subassembly 14. Forward clutch plate snap ring
I2RH0B510176-01