2006 SUZUKI SX4 Valve

Downloaded from www.Manualslib.com manuals search engine 5A-96 Automatic Transmission/Transaxle:
10) Remove valve body assembly referring to
“Automatic Transaxle Unit Disassembly”.
11) Remove pressure control solenoid valve and TCC
pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC
pressure control solenoid valve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body assembly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves
and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “Automatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to
procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valves InspectionS6RW0D5106020
CAUTION!
• Be very careful as dust etc. does enter
when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)Operation Check
Check pressure control solenoid valves (Pressure
control solenoid and TCC pressure control solenoid)
operation in the either manner of the following.
Using regulated DC power supply
1) Connect pressure control solenoid valve (1) with
regulated DC power supply (2) as shown in figure.
2) Turn regulated DC power supply switch ON and
increase voltage of power supply keeping current
within 1.0 A.
3) Check for gradual movement of valve (3) in the
direction of arrow “A” as voltage is increased.
4) Check movement of valve (3) in the direction of
arrow “B” as voltage is decreased.
5) Turn power supply switch OFF.
CAUTION!
Do not pass current 1.0 A or more, or
pressure control solenoid is burned out.

Not using regulated DC power supply
1) Connect pressure control solenoid valve (1) to
battery (2) setting 21 W bulb (4) on the way as
shown in figure.
2) Check for movement of valve (3) in the direction of
arrow “A”.
3) Disconnect pressure control solenoid valve (1) from
battery (2) and check movement of valve (3) in the
direction of arrow “B” as shown in figure.
CAUTION!
Set 21 W bulb on the way, or pressure control
solenoid valve is burned out.

1
I2RH01510071-01
I2RH0B510064-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-105
9) Remove fluid cooler pipes (1) and pipe unions (2).
10) Remove fluid level gauge (3) and fluid filler tube (4).
11) Remove oil pan (1) and oil pan gasket (2).
NOTE
• For removal of oil pan, do not turn
transaxle over as this will contaminate
valve body with foreign materials in
bottom of oil pan.
• When removing oil pan, tap around it
lightly with plastic hammer. Do not force it
off by using screwdriver or the like.

12) Remove oil strainer assembly (1).13) Disconnect connectors (2) from solenoid valves and
transmission fluid temperature sensor (1).
14) Remove valve body assembly bolts.
CAUTION!
Be careful not to let manual valve fall off
when removing valve body assembly.

NOTE
There are five kinds of bolts (bolts A (1), B (2),
C (3), D (4) and E (5)) fixing valve body
assembly.

15) Remove manual valve rod (1) from manual valve
lever (2), then remove valve body assembly (3).
43
12
I5RW0C510060-01
I2RH0B510086-01
I2RH0B510087-01
2
1
I5RW0C510038-02
I2RH0B510089-01
I2RH0B510090-01

Downloaded from www.Manualslib.com manuals search engine 5A-106 Automatic Transmission/Transaxle:
16) Remove valve body harness (1).
CAUTION!
When pulling valve body harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

17) Remove governor apply No.1 gasket (1).
18) Remove cooler check valve (1) and spring (2).19) Remove accumulator pistons and springs.
To remove C2 (1), C1 (2) and B1 (3) accumulator
pistons and springs, position rag on pistons to catch
each piston. To remove pistons, force low-pressure
compressed air (1 kg/cm
2, 15 psi, 100 kPa, max) into
hole (4) as shown in figure, and pop each piston into
rag.
NOTE
Do not push accumulator pistons with
fingers or anything before removing them.
Pushing them may cause compressed fluid
in accumulator to spew out of hole and get to
your face and clothes.

I2RH0B510091-01
I2RH0B510092-01
I2RH0B510093-01
I2RH0B510094-01

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 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 Automatic Transmission/Transaxle: 5A-135
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Shift solenoid valve-A and -B are identical
• After applying A/T fluid to new O-rings, fit them to
solenoid valves, then install solenoid valves to valve
body.
• Tighten solenoid valve bolts to specified torque
Tightening torque
Solenoid valve bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Solenoid valve bolt specification
Differential Assembly ComponentsS6RW0D5106052
Bolt Length “a” Pieces
A (1) 49 mm (1.93 in.) 5
B (2) 20 mm (0.79 in.) 1
C (3) 60 mm (2.36 in.) 1
1
1 1
3
2
"a"
I4RS0A510046-01
I5RW0C510064-01
1. Differential side RH bearing 5. Side bearing shim : Apply automatic transaxle fluid.
2. Output shaft speed sensor (VSS) drive gear 6. Final gear bolt : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
3. Differential case subassembly 7. Side bearing cup : Do not reuse.
4. Final gear 8. Differential side LH bearing