2006 SUZUKI SX4 manual transmission

Downloaded from www.Manualslib.com manuals search engine 5B-4 Manual Transmission/Transaxle:
5th & Reverse Gear Shift Cam
5th & reverse gear shift cam, cam guide return spring
and 5th to reverse interlock guide bolt are provided to
prevent the gear from being directly shifted from 5th to
reverse.
1) When shift lever is at neutral position between 3rd
and 4th gear, shift cam (2) is under guide bolt and
can turn freely clockwise (to 3rd gear) and
counterclockwise (to 4th gear).
2) When shift lever is shifted toward the right from
neutral position, shift and select shaft (1) moves up
but shift cam (2) is restricted by guide bolt and return
spring is contracted.3) When shift lever is shifted to 5th gear, shift & select
shaft (1) turns clockwise letting shift cam (2) off from
guide bolt and pushed up by return spring. In this
state, movement of shift cam is restricted by guide
bolt and therefore, gearshift to reverse is not
attainable.
4) When shift lever is shifted from neutral position
between 5th gear and reverse gear to reverse gear,
shift cam (2) turns counterclockwise to attain reverse
gear.
1. Shift & select shaft
3. Return spring (expanded)
4. Reverse select spring (expanded)
3. Reverse select spring (contracted)
I2RH01520003-02
I2RH01520004-01
I2RH01520005-01
3. Reverse select spring (expanded)
1. Shift & select shaft
3. Return spring (contracted)
4. Reverse select spring (contracted)
I2RH01520006-01
I2RH01520007-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-5
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS6RW0D5204001
Repair Instructions
Manual Transaxle Oil Level CheckS6RW0D5206001
1) Lift up vehicle and check oil leakage. Repair leaky
point, if any.
2) Remove oil level / filler plug (1) and check oil
contamination and oil level is lower end of oil level /
filler plug hole (2).
If oil is excessive dirty or insufficient, replace oil or
pour specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Condition Possible cause Correction / Reference Item
Gears slipping out of
meshWorn shift fork shaftReplace
Worn shift fork or synchronizer sleeveReplace
Weak or damaged locating springsReplace
Worn bearings on input shaft or
countershaftReplace
Worn chamfered tooth on sleeve and
gearReplace sleeve and gear
Hard shiftingInadequate lubricantReplenish
Improper clutch pedal free travelReplace clutch arm or master cylinder
Distorted or broken clutch discReplace
Damaged clutch pressure plateReplace clutch cover
Worn synchronizer ringReplace
Worn chamfered tooth on sleeve or gearReplace sleeve or gear
Worn gear shift control shaft joint bushReplace
Distorted shift shaftReplace
Broken gear shift / select control cablesReplace
NoiseInadequate or insufficient lubricantReplenish
Damaged or worn bearing(s)Replace
Damaged or worn gear(s)Replace
Damaged or worn synchronizer partsReplace
I5RW0A520004-01

Downloaded from www.Manualslib.com manuals search engine 5B-6 Manual Transmission/Transaxle:
Manual Transaxle Oil ChangeS6RW0D5206002
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check leakage.
If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil level / filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Pour new specified oil until oil level reaches bottom
of oil filler plug hole (3) as shown in figure.
NOTE
It is highly recommended to use API GL-4
75W-90 gear oil.

Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Manual transaxle oil capacity
Reference: 2.5 liters (5.3/4.4 US/lmp. pt.)7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lb-ft)
I5RW0A520005-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-7
Differential Side Oil Seal ReplacementS6RW0D5206003
1) Lift up vehicle and drain transaxle oil.
2) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove oil seal (1) by using special tool.
Special tool
(A): 09913–50121
4) Install a new oil seal (1) by using special tool.
NOTE
• When installing oil seal, face its spring
side inward.
• Install oil seal horizontally to surface of
case.

Special tool
(A): 09913–75810
(B): 09913–75510
Distance between case and right oil seal for 2WD
“a”: 9.5 – 10.5 mm (0.37 – 0.41 in.)
Distance between case and left oil seal
“b”: 0 – 1.0 mm (0 – 0.04 in.)5) Apply grease to oil seal lip and at the same time
check drive shaft where oil seal contacts and make
sure of its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
6) Insert drive shaft assembly and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
7) Pour transaxle oil referring to “Manual Transaxle Oil
Change”.
(A)
1I5RW0A520006-02
“b”
“a”
1, “A”
(A)(B)
I5RW0A520051-01

Downloaded from www.Manualslib.com manuals search engine 5B-8 Manual Transmission/Transaxle:
Gear Shift Control Lever and Cable ComponentsS6RW0D5206004
1
7
3
4
(a) 6
A
8(b)
2
(c)
5
9
A
I5RW0A520008-02
1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
2. Cable bracket bolt 7. Gear shift control lever assembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Gear shift lever boot 8. Cable grommet bolt : Do not reuse.
4. Gear shift control cable
: Apply grease 99000-25010 to cable end.9. Cable bracket
5. Gear select control cable
: Apply grease 99000-25010 to cable end.:13 N⋅m (1.3 kgf-m, 9.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Gear Shift Control Lever and Cable Removal
and Installation
S6RW0D5206005
Removal
1) Remove console box.
2) Disconnect cable ends (5) from pivot (6) of gear shift
control lever assembly by removing clip.
3) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly (2) while
pulling quick joint (4) as shown in figure.
4) Remove gear shift control lever assembly mounting
nuts (3) and gear shift lever assembly from floor
panel.
5) Disconnect gear shift and select control cables from
transaxle.
6) Remove cable grommet bolt, and then remove gear
shift and select control cables from floor panel.
Installation
Reverse removal procedure for installation nothing the
following.
• Tighten each bolts and nuts to specified torque
referring to “Gear Shift Control Lever and Cable
Components”.
• Adjust gear select control cable referring to “Gear
Select Control Cable Adjustment”.
Gear Select Control Cable AdjustmentS6RW0D5206006
1) Release lock plate (1) which restricts moving of
cable end holder (2).
2) Push cable end holder (2) out from adjuster (4) using
appropriate tool (3) to disengage cable.
36
5
2
3
41
I4RS0A520003-01
I4RS0A520004-01

Downloaded from www.Manualslib.com manuals search engine 5B-10 Manual Transmission/Transaxle:
3) Apply grease to pin (5) of gear shift control lever, and
then install adjuster (1) into pin of gear shift control
lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in the direction of A.
NOTE
At this time, do not apply force in the cable
operation direction B to adjuster.

5) Slide lock plate (3) in the direction of C, until it gets
over the claw (4) of cable end holder.
Back Up Light Switch Removal and InstallationS6RW0D5206007
Removal
1) Remove battery and tray with ECM.
2) Disconnect back up light switch coupler (1).
3) Remove back up light switch.
Installation
1) Apply oil to new O-ring (1) and tighten back up light
switch (2) to specified torque.
Tightening torque
Back up light switch (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
2) Connect back up light switch coupler.
3) Install battery and tray with ECM.
Back Up Light Switch InspectionS6RW0D5206008
Check back up light switch for function using ohmmeter.
Switch ON (Push): Continuity
Switch OFF (Release): No continuity
3
3
41
2
A C
1
B
5, “A”
I4RS0A520005-01
2. Gear shift and select shaft assembly
2
1I5RW0A520009-01
1 2, (a)
I3RH0A520006-01
I5RW0A520050-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-11
Manual Transaxle Unit ComponentsS6RW0D5206009
3
7(a)4
65
8
2[A]
1
10(a)
7(a) 9
(c)
11(b)
I5RW0A520010-02
[A]: Forward 5. Ground cable bolt 10. Transaxle to engine nut
1. Engine 6. Ground cable 11. Stiffener bolt
2. Transaxle 7. Transaxle to engine bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
3. Gear shift control cables 8. Clutch housing lower plate : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
4. Back up light switch connector 9. Clutch housing lower plate bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)