2006 SUZUKI SX4 lock

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).
1
2
I4RS0A510038-01
I2RH0B510127-01
I2RH0B510128-01
I2RH0B510129-01
I2RH0B510130-01
1
I4RS0A510039-01
I2RH0B510132-01

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.

I2RH0B510133-01
I2RH0B510134-01
I2RH0B510135-01
I2RH0B510136-01
I2RH0B510137-02

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).
I2RH0B510138-01
I2RH0B510139-01
I2RH0B510140-01
12I4RS0A510040-01

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).
I2RH0B510142-01
I2RH0B510143-01
I2RH0B510144-01
I2RH0B510145-01
I2RH0B510146-01
I2RH0B510147-01

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-133
3) Install countershaft LH bearing (1) with special tools
and hydraulic press.
Special tool
(A): 09913–84510
(B): 09925–88210
Valve Body Assembly ComponentsS6RW0D5106050
I2RH0B510214-01
I4RS0A510044-01
1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid.
2. Shift solenoid valve-A (No.1) 7. Valve body assembly : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Shift solenoid valve-B (No.2) 8. Manual valve : Do not reuse.
4. TCC pressure control solenoid valve 9. Solenoid lock plate
5. Timing solenoid valve 10. O-ring

Downloaded from www.Manualslib.com manuals search engine 5A-134 Automatic Transmission/Transaxle:
Valve Body Assembly Disassembly and
Reassembly
S6RW0D5106051
CAUTION!
When replacing pressure control solenoid
valve and/or TCC pressure control solenoid
valve, it is strictly required to replace it
together with valve body assembly as a set.
Replacing pressure control solenoid valve
and/or TCC pressure control solenoid valve
independently may cause excessive shift
shock.

Disassembly
1) Pull out manual valve (1).
2) Remove pressure control solenoid valve (1).
3) Remove TCC pressure control solenoid valve (1).4) Remove shift solenoid valve-A (1).
5) Remove shift solenoid valve-B (1).
6) Remove timing solenoid valve (1).
7) Remove temperature sensor clamp (1).
2. Solenoid lock plate
I2RH0B510216-01
I2RH0B510217-01
1
I4RS0A510045-01
I2RH0B510219-01
I2RH0B510220-01
I2RH0B510221-01
I2RH0B510222-01

Downloaded from www.Manualslib.com manuals search engine 5A-144 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS6RW0D5106058
CAUTION!
• Automatic transaxle consists of highly
precise parts. As even flaw in small part
may cause oil leakage or decrease in
function, check each part carefully before
installation.
• Clean all parts with compressed air. Never
use wiping cloths or rags.
• Before assembling new clutch or brake
discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding
or rotating surfaces of the parts before
assembly.
• Use Suzuki Super Grease “C” to retain
parts in place.
• Be sure to install thrust bearings and races
in correct direction and position.
• Make sure that snap ring ends are not
aligned with one of cutouts and are
installed in groove correctly.
• Do not use adhesive cements on gaskets
and similar parts.
• Be sure to torque each bolt and nut to
specification.

1) Install new manual shift shaft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.75 – 1.25 mm (0.03 – 0.05 in.)2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl rod (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever
(1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using
spring pin remover with 3 mm (0.12 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
I2RH0B510258-01
I2RH0B510259-01
I2RH0B510260-01
I2RH0B510261-01