2006 SUZUKI SX4 Oil ring

Downloaded from www.Manualslib.com manuals search engine 5A-130 Automatic Transmission/Transaxle:
Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Disassembly and
Reassembly
S6RW0D5106046
Disassembly
1) Remove snap ring by using special tools and
hydraulic press.
Special tool
(A): 09926–96030
(B): 09946–06710
CAUTION!
Do not press O/D and 2nd coast brake return
spring subassembly in over 1.0 mm (0.039
in.).
Excessive compression may cause damage
to O/D and 2nd coast brake return spring
subassembly and/or piston.

2) Remove O/D and 2nd coast brake return spring
assembly.
3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (2) of transaxle rear cover (1)
to remove O/D and 2nd coast brake piston.4) Remove O/D and 2nd coast brake piston front O-ring
(1) and rear O-ring (2).
5) Remove rear cover seal rings (1).
6) Remove rear cover plugs (1).
1. Transaxle rear cover
I2RH0B510201-01
I2RH0B510202-01
I2RH0B510203-01
I2RH0B510204-01
I2RH0B510205-01

Downloaded from www.Manualslib.com manuals search engine 5A-136 Automatic Transmission/Transaxle:
Differential Assembly Disassembly and
Reassembly
S6RW0D5106053
Disassembly
1) Remove final gear bolts (1), and then final gear (2).
2) Remove differential side RH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
3) Remove output shaft speed sensor (VSS) drive gear
(1).4) Remove differential side LH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
Reassembly
WARNING!
• When taking warmed final driven gear out
of vessel, use tongs or the like. Taking out
it with bare hand will cause severe burn.
• While installing warmed final driven gear,
use oven glove such as leather glove.
Picking up it with bare hand may cause
burn.

CAUTION!
Do not leave final driven gear in boiling water
for longer than 5 min. Overheating the gear
may cause strength reduction of gear.

1) Put final driven gear in water vessel, heat and
remove when it boils, then remove moisture.
NOTE
After removing moisture on final driven gear,
install final driven gear to differential case as
quickly as possible.

2. Differential case subassembly
I2RH0B510225-01
I2RH0B510226-01
I2RH0B510227-01
I2RH0B510228-01
I2RH0B510229-01

Downloaded from www.Manualslib.com manuals search engine 5A-138 Automatic Transmission/Transaxle:
Torque Converter Housing Disassembly and
Reassembly
S6RW0D5106055
Disassembly
1) Remove fluid reservoir RH plate (1) and lubrication
tube clamp (2).
2) Remove lubrication LH tube (1) and RH tube (2).
NOTE
Do not bend lubrication tube with excessive
force.

3) Remove differential side oil seal (1).4) Remove countershaft RH bearing cup by using
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
5) Remove differential side RH bearing cup by using
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
6) Remove torque converter case plugs (1).
I2RH0B510236-01
I2RH0B510237-01
I2RH0B510238-01
I2RH0B510239-01
I2RH0B510240-01
I2RH0B510241-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-139
Reassembly
1) After applying A/T fluid to new O-rings, fit them to
housing plugs. Finally install plugs to torque
converter housing.
Tightening torque
Torque converter housing plug (a): 7.5 N·m (0.75
kgf-m, 5.5 lb-ft)
2) Using special tools, assemble differential side RH
bearing cup.
Special tool
(A): 09924–74510
(B): 09944–88220
3) Using special tool, install countershaft RH bearing
cup.
Special tool
(A): 09924–74510
(B): 09944–882204) Using special tools, install new differential side oil
seal to torque converter housing.
Special tool
(A): 09913–75510
Differential side oil seal installing depth
“a”: 13.2 – 14.2 mm (0.52 – 0.56 in.)
5) Apply grease to oil seal lip.
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
6) Install lubrication LH tube (1) and RH tube (2).
7) Install fluid reservoir RH plate (1) and lubrication
tube clamp (2).
Tightening torque
Lubrication tube clamp bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
Fluid reservoir RH plate bolt (b): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
I2RH0B510242-01
(A)
(B)
I3RM0B510063-01
(B)(A)
I3RM0B510064-01
(A) “a”
“A”
I5RW0C510065-02
I2RH0B510237-01
I2RH0B510246-01

Downloaded from www.Manualslib.com manuals search engine 5A-140 Automatic Transmission/Transaxle:
Transaxle Case Disassembly and ReassemblyS6RW0D5106056
Disassembly
1) Remove differential side oil seal (1).
2) Remove countershaft LH bearing cup and shim with
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
3) Remove differential side LH bearing cup and shim
with special tools.
Special tool
(A): 09944–96011
(B): 09942–15511Reassembly
1) Using special tools, assemble shim and differential
side LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
2) Using special tools, assemble shim and countershaft
LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
I2RH0B510247-01
I2RH0B510248-01
I2RH0B510249-01
(B) (A)
I3RM0B510065-01
(B)(A)
I3RM0B510066-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-141
3) Install new differential side oil seal to transaxle case
by using special tools.
Special tool
(A): 09913–75810
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip.
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S6RW0D5106057
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the above conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored,
replace all discs.
• Before assembling new discs, soak them
in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discoloration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return springs.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.

(A)“a”
“A”
I5RW0C510066-02
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01

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

Downloaded from www.Manualslib.com manuals search engine 5A-146 Automatic Transmission/Transaxle:
12) Install 1st and reverse brake plate snap ring so that
its both ends would be positioned in correct locations
as shown in figure.
13) Using special tools, measure 1st and reverse brake
piston stroke when compressed air (400 – 800 kPa,
4 – 8 kg/cm
2, 57 – 113 psi) is brown through oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.791 – 1.489 mm (0.0311 – 0.0586 in.)14) Install reduction drive gear (1) to transaxle case (3)
by using special tools and hydraulic press.
CAUTION!
• Do not use transaxle case as groundwork
to press fit reduction drive gear.
• 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.

NOTE
When replacing reduction drive gear, replace
it together with reduction driven gear as a
set.

Special tool
(A): 09951–18210
(B): 09944–78210
15) Install parking lock pawl (1) and spring (2). Apply A/T
fluid to parking lock pawl shaft, then insert it into
transaxle case.
[A]: Correct [B]: Incorrect
I2RH0B510268-01
I2RH0B510269-01
2. Stand that can slightly lift transaxle case.
I2RH0B510270-01
I2RH0B510271-01