2006 SUZUKI SX4 Oil ring

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 5B-12 Manual Transmission/Transaxle:
Manual Transaxle Unit Dismounting and
Remounting
S6RW0D5206010
Dismounting
1) Drain coolant.
2) Remove battery and tray with ECM.
3) Remove air cleaner case and resonator.
4) Remove clutch fluid pipe referring to “Clutch Fluid
Pipe Removal and Installation in Section 5C”.
5) Disconnect back up light switch coupler and undo
wiring harness clamps.
6) Disconnect gear shift and gear select control cables
(1) from transaxle.
7) Remove earth cable from transaxle.
8) Remove water inlet pipe.
9) Remove starting motor referring to “Starting Motor
Dismounting and Remounting in Section 1I”.
10) Remove transaxle to engine bolts (1) of upper side.
11) Drain transaxle oil and transfer oil, if equipped.
12) Remove engine under covers.
13) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
14) Remove exhaust No.1, No.2 and No.3 pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
15) Remove suspension frame, engine front mounting
member and engine mounting member referring to
“Front Suspension Frame, Stabilizer Bar and/or
Bushing Removal and Installation in Section 2B” and
“Engine Mountings Components in Section 1D”.16) Remove transfer referring to “Transfer Dismounting
and Remounting in Section 3C”, if equipped.
17) Remove clutch housing lower plate.
18) Support transaxle with transmission jack.
19) Remove left mounting (1) and left mounting bracket
(2).
20) Remove stiffener bolts (2), transaxle to engine bolts
(1) and nut of lower side, and then lower transaxle.
Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer
when installing it into differential gear.

Reverse dismounting procedure for remounting of
transaxle, noting the following points.
• Tighten each bolts and nuts to specified torque
referring to “Manual Transaxle Unit Components” and
“Engine Mountings Components in Section 1D”.
• Set each clamp for wiring securely.
• Fill transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change” and “Transfer Oil Change in
Section 3C”.
• Connect battery and check function of engine, clutch
and transaxle.
1
I5RW0A520011-01
1
I5RW0A520012-01
1
2
I5RW0A520013-01
1
2I5RW0A520014-01

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
Manual Transaxle Assembly ComponentsS6RW0D5206014
I5RW0A520018-03
1. Transaxle right case 22. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case
: Apply sealant 99000-31260 to mating surface of left case and right
case.23. 5th gear shift fork
3. Gear shift and select shaft assembly
: Apply sealant 99000-31260 to mating surface of guide case and left
case.24. Needle bearing
4. Transaxle left case plate 25. Input shaft 5th gear
5. Transaxle side cover
: Apply sealant 99000-31260 to mating surface of side cover and left
case.26. Reverse gear shift lever
6. Back up light switch 27. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring28. Reverse gear shaft
8. Differential assembly 29. Washer
9. Oil level / filler plug
: Apply sealant 99000-31260 to all around thread part of plug.30. Reverse idler gear

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-17
Fifth Gear Disassembly and ReassemblyS6RW0D5206015
Disassembly
1) Remove cover bolts and take off transaxle side
cover.
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using special tool, remove circlip (1).
Special tool
: 09900–06107
3) Remove shift fork shaft bolt (2).
4) Remove gear shift fork (3) and 5th gear all together.
Use gear puller for removal if spline fitting of hub is
tight.5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and
then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
10. Oil drain plug
: Apply sealant 99000-31260 to all around thread part of plug.31. Reverse shaft bolt
: Apply sealant 99000-31260 to thread part of bolt.
11. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.32. Washer
12. Left case plate bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.33. Oil seal
: Apply SUZUKI SUPER GREASE A
99000-25010 to Oil seal lip.
13. Side cover bolts 34. Outer race
14. Transaxle case bolts 35. Shim
15. 5th speed synchronizer ring 36. Oil gutter
16. 5th speed synchronizer lever : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
17. 5th speed sleeve & hub : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
18. Circlip: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
19. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
20. Countershaft 5th gear : Do not reuse.
21. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.: Apply transaxle oil.
32
1
I4RH01520015-01
(A)
2
1
I4RH01520016-01
I4RH01520017-01

Downloaded from www.Manualslib.com manuals search engine 5B-18 Manual Transmission/Transaxle:
Reassembly
1) Install countershaft 5th gear (1) to countershaft
facing machined boss “A” inward.
2) Apply transaxle oil to needle bearing, and install it to
input shaft.
3) Install input shaft 5th gear (1) to input shaft.
4) Install special tool in order to stop shaft rotation.
Special tool
(A): 09927–76060
5) Tighten new countershaft nut (2) to specified torque,
and caulk nut securely.
Tightening torque
Countershaft nut (a): 100 N·m (10.0 kgf-m, 75.0
lb-ft)
6) Assemble 5th speed synchronizer sleeve (1), hub
(2), 5th speed synchronizer levers (3) and
synchronizer ring (4) as follows.a) Install hub (1) to 5th speed synchronizer sleeve
(2) in specified direction as shown in figure.
b) Fit 5th speed synchronizer levers (1) to hub (2) in
specified position as shown in figure.
NOTE
Align protrusion “A” of 5th speed
synchronizer levers (1) with groove of hub
(2).

c) Install synchronizer ring (1) to hub (2) in
specified direction as shown in figure.
A: Machined boss (Inside)
B: No machining (Outside)
I2RH01520088-01
(A)
2, (a)
1
I4RH01520047-01
I4RH01520054-01
A: Chamfered side
B: Long boss
1
2 B
A
I4RH01520048-01
1A
2 A
I4RH01520049-01
1
2
I4RH01520055-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-21
Reassembly
1) Install differential assembly into right case.
2) Join input shaft (5), countershaft (4), low speed gear
shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, then install them into right
case (1) so as not to damage oil seal by input shaft
spline.
NOTE
• Input shaft right bearing on shaft can be
installed into right case (1) by tapping shaft
with plastic hammer.
• Make sure that countershaft is engaged
with final gear while installing.

3) Install 5th & reverse gear shift shaft (1) with 5th &
reverse gear shift guide shaft (2) into right case (5).
Reverse gear shift arm (4) has to be joined with
reverse gear shift lever (3) at the same time.4) Make reverse idler gear (1) with reverse gear shift
lever (2), insert reverse gear shaft (3) and washer (6)
into case (4) through idler gear and then align bolt
hole “a” in shaft with notch “b” in case.
5) Fasten reverse gear shift lever bolts (5) after
applying thread lock cement.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
NOTE
Check to confirm that reverse gear shift lever
end has clearance “c” to idler gear groove.

Distance between lever end and idler gear shaft
“c”: 0.5 – 1.0 mm (0.02 – 0.04 in.)
I2RH01520080-01
I3RH0A520013-01
I5RW0A520022-02

Downloaded from www.Manualslib.com manuals search engine 5B-24 Manual Transmission/Transaxle:
16) Place left case plate (2) inserting its end in groove of
shift guide shaft (4) and then tighten bolts (1) to
which thread lock cement has been applied.
NOTE
After tightening bolts, make sure that
countershaft can be rotated by hand feeling
certain load.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Right Case Disassembly and ReassemblyS6RW0D5206017
Disassembly
1) Remove differential side oil seal from right case
referring to “Differential Side Oil Seal Replacement”,
if necessary.
2) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.3) Remove input shaft oil seal by using special tool, if
necessary.
Special tool
(A): 09913–75830
4) Pull out countershaft right bearing outer race by
using special tools, if necessary.
Special tool
(A): 09930–30104
(B): 09941–64511
Reassembly
1) Install input shaft oil seal facing its spring side
upward until it becomes flush with case surface. Use
special tool and hammer for installation and apply
grease to oil seal lip.
: Grease 99000–25011 (SUZUKI Super Grease A)
Special tool
(A): 09913–76010
3. Input shaft
5. Countershaft
I2RH01520087-01
2
1
I4RH01520024-01
(A)
I5RW0A520026-01
(A)
(B)
I5RW0A520027-01
(A)
I5RW0A520028-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-25
2) Install countershaft right bearing outer race (1) by
using special tools and hammer.
Special tool
(A): 09913–75821
(B): 09924–84510–004
3) Install differential side bearing outer race by using
special tool and hammer.
Special tool
(A): 09924–74510
(B): 09925–14520Left Case Disassembly and ReassemblyS6RW0D5206018
Disassembly
1) Removal oil gutter (1), if necessary.
2) Remove oil seal using flat end rod or the like.
3) Remove differential side bearing outer race (1) using
special tools.
Special tool
(A): 09942–15511
(B): 09944–96011
I5RW0A520029-02
(A)
(B)
I5RW0A520030-01
I4RH01520028-01
(A)
(B)
1I5RW0A520031-01