2006 SUZUKI SX4 Automatic transaxle components

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-87
2) Remove adjuster (cable end) from select lever pin of
select lever assembly.
3) Remove adjuster (cable end) from select lever pin of
select lever assembly.
4) Release lock plate (1) which restrict moving of cable
end holder (2).
5) Push cable end holder (1) out from eye-end (2) using
an appropriate tool (3) to disengage cable.
6) Shift select lever to “N” position.
7) Apply grease to select lever pin and install adjuster
(cable end) to it.
: Grease 99000–25011 (SUZUKI Super Grease
A)
8) With both select lever and transmission range
sensor kept each “N” position, drive cable end holder
(1) in until it locks cable.
9) Slide lock plate (2) to secure cable end holder in
position.
10) After select cable was installed, check for the
following.
• Push vehicle with select lever shifted to “P” range.
Vehicle should not move.
• Vehicle can not be driven in “N” range.• Vehicle can be driven in “D”, “3”, “2” and “L”
ranges.
• Vehicle can be backed in “R” range.
Key Interlock Cable Removal and InstallationS6RW0D5106026
NOTE
Don’t bend interlock cable excessively when
removing and installing it, or system will not
operate correctly.

Removal
1) If the vehicle is equipped with air bag system,
disconnect negative cable at battery and disable air
bag system, referring to “Disabling Air Bag System in
Section 8B”.
2) Remove steering column cover.
3) Turn ignition switch to ACC position.
4) Pull out key interlock cable (1) from key cylinder
cover (2) while pressing checkhook with slotted
screwdriver (3) or the like.
5) Turn ignition switch to LOCK position.
6) Remove console box referring to “Console Box
Components in Section 9H”.
7) Detach cable end (1) from interlock cam (2) while
pressing claws (3) of interlock cam boss.
At this time, be careful not to cause damage to its
claws.
Detach cable casing cap (4) from bracket (5) while
pressing checkhook.
8) Remove interlock cable.
I2RH01510046-01
I2RH01510047-01
I3RM0B510037-01
2
13I5RW0C510045-01
4
5 3 12
4
I5RW0C510046-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-99
Automatic Transaxle Unit ComponentsS6RW0D5106028
I5RW0C510050-01
1. Drive plate 6. Transaxle and engine fastening bolt : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft)
2. Drive plate bolt 7. Transaxle and engine fastening nut : 69 N⋅m (6.9 kgf-m, 50.0 lb-ft)
3. Drive plate to torque converter bolt 8. Transaxle housing lower plate : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
4. Torque converter 9. Transaxle housing lower plate bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
5. Engine oil pan bolt : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 5A-102 Automatic Transmission/Transaxle:
Automatic Transaxle Assembly ComponentsS6RW0D5106030
I5RW0C510057-01

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-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 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

Downloaded from www.Manualslib.com manuals search engine 5A-128 Automatic Transmission/Transaxle:
Forward Clutch Piston Lip and Forward Clutch
Balancer Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.Forward Clutch Drum Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
2nd Brake Piston Assembly ComponentsS6RW0D5106043
2nd Brake Piston Assembly Disassembly and
Reassembly
S6RW0D5106044
Disassembly
1) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of 2nd brake cylinder (3)
to remove 2nd brake piston (2).
I2RH0B510194-01
I2RH0B510195-01
I2RH0B510196-01
1. 2nd brake cylinder 4. Outer O-ring
2. 2nd brake piston : Apply automatic transaxle fluid.
3. Inner O-ring : Do not reuse.
I2RH0B510197-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-129
2) Remove inner O-ring (1) and outer O-ring (2).Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new O-rings. Apply A/T fluid to the O-rings,
before installation.
• Install 2nd brake piston (1) to which A/T fluid is
applied to 2nd brake cylinder (2).
Do not damage O-ring when installing 2nd brake
piston.
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly ComponentsS6RW0D5106045
I2RH0B510198-01
I2RH0B510199-01
I5RW0C510063-01
1. Snap ring 5. O/D and 2nd coast brake piston 9. Rear cover plug O-ring
2. O/D and 2nd coast brake return spring subassembly 6. Rear cover seal ring : Apply automatic transaxle fluid.
3. O/D and 2nd coast brake piston front O-ring 7. Transaxle rear cover : Do not reuse.
4. O/D and 2nd coast brake piston rear O-ring 8. Rear cover plug : 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)