2006 SUZUKI SX4 321

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-157
72) After applying A/T fluid to new O-ring, fit it to valve
body harness connector (3), then install valve body
harness to transaxle case.
CAUTION!
When put valve body harness (1) into
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow entrance of case.
Careless sensor treatment might cause
sensor malfunction.

Tightening torque
Valve body harness connector bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
73) Install manual valve rod (1) to manual valve lever (3)
and then install valve body assembly (2) to transaxle
case.
74) Tighten valve body bolts to specified torque.
Tightening torque
Valve body bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)Valve body bolt length
75) Connect solenoid connectors to solenoid valves
identifying their installing positions by wire colors,
and install transmission fluid temperature sensor to
its clamp.
Solenoid valve coupler specification
I2RH0B510321-01
I2RH0B510322-01
Bolt Length “a” Pieces
A (1) 20 mm (0.79 in.) 6
B (2) 28 mm (1.10 in.) 5
C (3) 49 mm (1.93 in.) 1
D (4) 36 mm (1.42 in.) 1
E (5) 40 mm (1.58 in.) 1
Solenoid valve coupler Wire color
Shift solenoid valve-A (No.1) (1) White
Shift solenoid valve-B (No.2) (2) Black
Timing solenoid valve (3) Yellow
TCC solenoid valve (4)Light green /
Brown
Pressure control solenoid valve (5) Gray / Green
Transmission fluid temperature
sensor (6)Orange
I2RH0B510323-01
1 4
6
3
2
5
I5RW0C510067-02

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
Manual Transaxle Assembly ComponentsS6RW0D5206014
I5RW0A520018-03
1. Transaxle right case 22. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case
: Apply sealant 99000-31260 to mating surface of left case and right
case.23. 5th gear shift fork
3. Gear shift and select shaft assembly
: Apply sealant 99000-31260 to mating surface of guide case and left
case.24. Needle bearing
4. Transaxle left case plate 25. Input shaft 5th gear
5. Transaxle side cover
: Apply sealant 99000-31260 to mating surface of side cover and left
case.26. Reverse gear shift lever
6. Back up light switch 27. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring28. Reverse gear shaft
8. Differential assembly 29. Washer
9. Oil level / filler plug
: Apply sealant 99000-31260 to all around thread part of plug.30. Reverse idler gear

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-17
Fifth Gear Disassembly and ReassemblyS6RW0D5206015
Disassembly
1) Remove cover bolts and take off transaxle side
cover.
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using special tool, remove circlip (1).
Special tool
: 09900–06107
3) Remove shift fork shaft bolt (2).
4) Remove gear shift fork (3) and 5th gear all together.
Use gear puller for removal if spline fitting of hub is
tight.5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and
then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
10. Oil drain plug
: Apply sealant 99000-31260 to all around thread part of plug.31. Reverse shaft bolt
: Apply sealant 99000-31260 to thread part of bolt.
11. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.32. Washer
12. Left case plate bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.33. Oil seal
: Apply SUZUKI SUPER GREASE A
99000-25010 to Oil seal lip.
13. Side cover bolts 34. Outer race
14. Transaxle case bolts 35. Shim
15. 5th speed synchronizer ring 36. Oil gutter
16. 5th speed synchronizer lever : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
17. 5th speed sleeve & hub : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
18. Circlip: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
19. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
20. Countershaft 5th gear : Do not reuse.
21. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.: Apply transaxle oil.
32
1
I4RH01520015-01
(A)
2
1
I4RH01520016-01
I4RH01520017-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-19
7) Fit 5th gear shift fork (1) to sleeve (3) and hub (2)
assembly, and install them into input shaft and gear
shift shaft, aligning punch mark (4) with matching
mark (5) on input shaft.
8) Tighten shift fork shaft bolt (2) to which thread lock
cement has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Shift fork shaft bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-
ft)
9) Using special tool, install new circlip (1) to input shaft
(3).
Special tool
: 09900–0610710) Clean mating surface of both left case and side
cover (1), apply sealant to side cover as shown in
figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate it with left case, and
then tighten side cover bolts with specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Manual Transaxle Assembly Disassembly and
Reassembly
S6RW0D5206016
Disassembly
1) Remove left case plate bolts (1), and take off left
case plate (2).
I3RH0A520080-01
2, (a), “A”
13
I5RW0A520019-013. Input shaft
I5RW0A520020-01
I4RH01520018-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-21
Reassembly
1) Install differential assembly into right case.
2) Join input shaft (5), countershaft (4), low speed gear
shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, then install them into right
case (1) so as not to damage oil seal by input shaft
spline.
NOTE
• Input shaft right bearing on shaft can be
installed into right case (1) by tapping shaft
with plastic hammer.
• Make sure that countershaft is engaged
with final gear while installing.

3) Install 5th & reverse gear shift shaft (1) with 5th &
reverse gear shift guide shaft (2) into right case (5).
Reverse gear shift arm (4) has to be joined with
reverse gear shift lever (3) at the same time.4) Make reverse idler gear (1) with reverse gear shift
lever (2), insert reverse gear shaft (3) and washer (6)
into case (4) through idler gear and then align bolt
hole “a” in shaft with notch “b” in case.
5) Fasten reverse gear shift lever bolts (5) after
applying thread lock cement.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
NOTE
Check to confirm that reverse gear shift lever
end has clearance “c” to idler gear groove.

Distance between lever end and idler gear shaft
“c”: 0.5 – 1.0 mm (0.02 – 0.04 in.)
I2RH01520080-01
I3RH0A520013-01
I5RW0A520022-02

Downloaded from www.Manualslib.com manuals search engine 5B-22 Manual Transmission/Transaxle:
6) Clean mating surfaces of both right and left cases,
apply sealant to left case (2) as shown in the figure
by such amount that its section is 1.5 mm (0.059 in.)
in diameter then mate it with right case (1).
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
7) Tighten case bolts (3) from outside and tighten
another case bolts from clutch housing side to
specified torque.
Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
8) Install reverse shaft bolt (4) to which thread lock
cement has been applied, with aluminum washer
and tighten it to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Reverse shaft bolt (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft)9) Check locating springs (2, 4 and 5) for deterioration
and replace with new ones as necessary.
Locating spring
10) Install steel balls (3) and locating springs (2, 4 and 5)
for respective gear shift shaft and tighten bolts (1) to
which thread lock cement has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Gear shift locating bolt (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
11) Install new snap ring (1) using special tool.
Special tool
(A): 09900–06107
I5RW0A520023-01
Locating spring free length Standard Service limit
Low speed (2)53.1 mm
(2.091 in.)47.8 mm
(1.881 in.)
High speed (4)45.9 mm
(1.807 in.)41.4 mm
(1.629 in.)
5th & reverse (5)29.9 mm
(1.777 in.)27.0 mm
(1.062 in.)
2. Input shaft
3. Input shaft left bearing
1, (a), “A”
2
3
4
5
I5RW0A520024-02
1 (A)
2
3
I3RH0A520016-01

Downloaded from www.Manualslib.com manuals search engine 5B-24 Manual Transmission/Transaxle:
16) Place left case plate (2) inserting its end in groove of
shift guide shaft (4) and then tighten bolts (1) to
which thread lock cement has been applied.
NOTE
After tightening bolts, make sure that
countershaft can be rotated by hand feeling
certain load.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Right Case Disassembly and ReassemblyS6RW0D5206017
Disassembly
1) Remove differential side oil seal from right case
referring to “Differential Side Oil Seal Replacement”,
if necessary.
2) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.3) Remove input shaft oil seal by using special tool, if
necessary.
Special tool
(A): 09913–75830
4) Pull out countershaft right bearing outer race by
using special tools, if necessary.
Special tool
(A): 09930–30104
(B): 09941–64511
Reassembly
1) Install input shaft oil seal facing its spring side
upward until it becomes flush with case surface. Use
special tool and hammer for installation and apply
grease to oil seal lip.
: Grease 99000–25011 (SUZUKI Super Grease A)
Special tool
(A): 09913–76010
3. Input shaft
5. Countershaft
I2RH01520087-01
2
1
I4RH01520024-01
(A)
I5RW0A520026-01
(A)
(B)
I5RW0A520027-01
(A)
I5RW0A520028-01

Downloaded from www.Manualslib.com manuals search engine 5B-26 Manual Transmission/Transaxle:
Reassembly
1) If oil gutter has been removed, install it with bolt to
which thread lock cement has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Oil gutter bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Select differential side shim as follows.
a) Keep pushing outer race (4) with the power of 35
N (3.5 kgf) and turn differential case 10 times or
more.
b) Measure distance “a” of differential assembly (1).
c) Measure depth “b” of left case (2) and “c” of right
case (3).
d) Calculate the clearance of “d” by the following
expressions.3) Select shim closest to clearance “d” from among the
following available sizes.
Available shim thickness
4) Put shim and then install differential side bearing
outer race using special tools. Clearance of “d” = Depth “b” + Depth “c” – Distance “a”
[A]: Press 35 N (3.5 kgf)
I2RH01520043-01
I7RW01520013-01
Clearance “d” Select shim
0.800 – 0.839 mm
(0.0315 – 0.0330 in.)1.00 mm (0.0394 in.)
0.840 – 0.879 mm
(0.0331 – 0.0345 in.)1.04 mm (0.0409 in.)
0.880 – 0.919 mm
(0.0346 – 0.0362 in.)1.08 mm (0.0425 in.)
0.920 – 0.959 mm
(0.0362 – 0.0378 in.)1.12 mm (0.0441 in.)
0.960 – 0.999 mm
(0.0378 – 0.0393 in.)1.16 mm (0.0457 in.)
1.000 – 1.039 mm
(0.0394 – 0.0409 in.)1.20 mm (0.0472 in.)
1.040 – 1.079 mm
(0.0409 – 0.0425 in.)1.24 mm (0.0488 in.)
1.080 – 1.119 mm
(0.0425 – 0.0441 in.)1.28 mm (0.0504 in.)
1.120 – 1.159 mm
(0.0441 – 0.0456 in.)1.32 mm (0.0520 in.)
1.160 – 1.199 mm
(0.0457 – 0.0472 in.)1.36 mm (0.0535 in.)
1.200 – 1.239 mm
(0.0472 – 0.0488 in.)1.40 mm (0.0551 in.)
1.240 – 1.279 mm
(0.0488 – 0.0504 in.)1.44 mm (0.0567 in.)
1.280 – 1.319 mm
(0.0504 – 0.0519 in.)1.48 mm (0.0583 in.)
1.320 – 1.359 mm
(0.0520 – 0.0535 in.)1.52 mm (0.0598 in.)
1.360 – 1.399 mm
(0.0535 – 0.0551 in.)1.56 mm (0.0614 in.)
1.400 – 1.439 mm
(0.0551 – 0.0567 in.)1.60 mm (0.0630 in.)
1.440 – 1.479 mm
(0.0567 – 0.0582 in.)1.64 mm (0.0646 in.)
1.480 – 1.529 mm
(0.0583 – 0.0602 in.)1.68 mm (0.0661 in.)