2006 SUZUKI SX4 torque

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-143
Countershaft bearing preload
1) After applying A/T fluid to countershaft assembly (1)
and differential assembly (2), fit them.
2) Install torque converter housing to transaxle case,
then tighten bolts to specified torque.
Tightening torque
Torque converter housing bolt: 33 N·m (3.3 kgf-
m, 24.0 lb-ft)
3) Measure bearing preload (b) by using special tool.
Special tool
(A): 09928–06050
Countershaft bearing preload (b) measured as
starting torque
In the case of new bearing: 0.33 – 0.76 N⋅m (3.3 –
7.6 kg-cm, 0.24 – 0.55 lb-ft)
In the case of reused bearing: 0.17 – 0.38 N⋅m
(1.7 – 3.8 kg-cm, 0.12 – 0.28 lb-ft)4) If bearing preload is out of specification, select shim
with suitable thickness from among the list below
and replace it. Then adjust countershaft bearing
preload within specification.
Available shim thickness
5) Remove differential assembly and countershaft
assembly. Countershaft bearing
preload=(b) – Differential side bearing
preload (a)
I2RH0B510257-01
I3RM0B510067-01
Thickness Identification mark
1.70 (0.066 in.) 1
1.75 (0.068 in.) 2
1.80 (0.070 in.) 3
1.85 (0.072 in.) 4
1.90 (0.074 in.) 5
1.93 (0.075 in.) 6
1.96 (0.077 in.) 7
1.99 (0.078 in.) A
2.02 (0.079 in.) B
2.05 (0.080 in.) C
2.08 (0.081 in.) D
2.11 (0.083 in.) E
2.14 (0.084 in.) F
2.17 (0.085 in.) G
2.20 (0.086 in.) H
2.25 (0.088 in.) K
2.30 (0.090 in.) L
2.35 (0.092 in.) M
2.40 (0.094 in.) N
2.45 (0.096 in.) P
2.50 (0.098 in.) Q
2.55 (0.100 in.) R
2.60 (0.102 in.) S
2.65 (0.104 in.) U
2.70 (0.106 in.) W

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

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-145
6) Install parking lock pawl bracket (1) to transaxle
case.
Tightening torque
Parking lock pawl bracket bolt (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
7) After applying A/T fluid to new O-rings, install them
to 1st and reverse brake piston (3).
8) Install 1st and reverse brake piston (1) to transaxle
case (2).
NOTE
Be careful not to damage O-ring when
installing 1st and reverse brake piston.

9) Install 1st and reverse brake return spring
subassembly (1) to transaxle case (2).
10) Apply A/T fluid to 1st and reverse brake discs (3),
separator plates (2) and retaining plate (1), then
install them to transaxle case.
11) Compress 1st and reverse brake return spring using
special tool and hydraulic press, then attach snap
ring.
CAUTION!
Do not damage 1st and reverse brake return
spring subassembly discs, plates and piston
by pressing in 1st and reverse brake return
spring subassembly passing through its
original installing position over 0.8 mm (0.031
in.).

Special tool
(A): 09926–97620
1. Inner O-ring 2. Outer O-ring
I2RH0B510262-01
I2RH0B510263-01
I2RH0B510264-01
I2RH0B510265-01
I2RH0B510266-01
I2RH0B510267-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
16) Install new planetary ring gear subassembly (1) to
reduction drive gear (3) by using special tools and
hydraulic press.
CAUTION!
• Do not reuse planetary ring gear
subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.
• Do not use transaxle case as groundwork
to press fit planetary ring gear
subassembly.
• Do not give load more than 20 kN (2000 kg,
4410 lb) with hydraulic press. Otherwise, it
may result in damaging reduction drive
gear bearing.

Special tool
(A): 09951–18210
(B): 09944–7821017) Using a small torque wrench, while turning to
counter drive gear 100 rpm and measure the
preload.
CAUTION!
• Do not tighten nut over the specifications
so that reduction drive gear nut would not
be broken.
• Carry out this procedure on rubber mat in
order not to damage transaxle case.

Reduction drive gear bearing preload measured
as starting torque
Standard: 0.05 – 0.35 N⋅m (0.5 – 3.5 kg-cm, 0.036
– 0.253 lb-ft)
18) Caulk reduction drive gear nut (1).
19) Apply A/T fluid to planetary gear assembly (1), then
fit it to planetary ring gear assembly.
2. Stand that can slightly lift transaxle case.
I2RH0B510272-01
I2RH0B510273-01
I2RH0B510274-01
1
I2RH0B510275-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-153
48) Install transaxle rear cover assembly on transaxle
case.
49) Install hook (2) to location shown in figure.
50) Tighten rear cover bolts (1).
Tightening torque
Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
51) Install fluid reservoir LH plate (1).
Tightening torque
Fluid reservoir LH plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
52) After applying A/T fluid to new governor apply No.2
gasket (1), install it to transaxle case.53) After applying A/T fluid to differential assembly (1)
and countershaft assembly (2), install them to
transaxle case.
54) After applying A/T fluid to direct clutch hub (1), install
it to planetary gear assembly.
55) After applying A/T fluid to input shaft rear thrust
bearing (1) and thrust bearing race (2), install them
into direct clutch hub (3).
56) After applying A/T fluid to input shaft front thrust
bearing (1), install it to direct clutch assembly (2).
I3RM0B510068-01
I2RH0B510303-01
I2RH0B510304-01
1
2
I4RS0A510036-01
I2RH0B510306-01
I2RH0B510307-01
I2RH0B510308-01

Downloaded from www.Manualslib.com manuals search engine 5A-154 Automatic Transmission/Transaxle:
57) Apply A/T fluid to direct clutch assembly (1).
Install direct clutch assembly while rotating
clockwise and counterclockwise frequently to fit
clutch discs to mating hub.
NOTE
Before installation, align teeth of direct clutch
discs to facilitate installation.

58) Check for correct installation of direct clutch
assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
direct clutch assembly, direct clutch hub and reinstall
them properly.
Distance between direct clutch assembly and
mating surface of transaxle case
“a”: 10.5 – 11.3 mm (0.413 – 0.445 in.)59) Install oil pump assembly (1) to transaxle case.
Tightening torque
Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
60) Make sure that input shaft (1) turns smoothly.
I2RH0B510309-01
“a”
“a”
1
2
I2RH0B510310-01
I2RH0B510311-01
I2RH0B510312-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-155
61) Measure input shaft thrust play.
Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
When input shaft thrust play is out of specification,
select input shaft front thrust bearing with proper
thickness from among the following table and
replace it.
Available input shaft front thrust bearing
thickness
62) After applying A/T fluid to new O-ring, fit it to
breather union (2). Then install breather union to
transaxle case.
63) Install breather hose (1).
64) Wipe off and clean mating surface between
transaxle case (1) and torque converter housing.
65) Apply sealant to torque converter housing by using a
nozzle (2) as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)66) Install torque converter housing to transaxle case,
tighten bolts to specified torque.
CAUTION!
Apply sealant to threads of four bolts shown
in figure before tightening.

“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Tightening torque
Torque converter housing bolt (a): 33 N·m (3.3
kgf-m, 24.0 lb-ft)
67) After applying A/T fluid to new O-ring, fit it to
transaxle case plug (1). Then install the transaxle
case plug to transaxle case (2).
Tightening torque
Transaxle case plug (a): 7.5 N·m (0.75 kgf-m, 5.5
lb-ft) ThicknessOutside
diameterInside diameter
3.45 mm
(0.14 in.)48.5 mm
(1.90 in.)32.9 mm
(1.30 in.)
4.05 mm
(0.16 in.)48.5 mm
(1.90 in.)32.5 mm
(1.28 in.)
I2RH0B510313-01
I2RH0B510314-01
12
“A”
I2RH0B510315-01
I3RM0B510069-01
I2RH0B510317-01

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