2006 SUZUKI SX4 Manual Transaxle Oil Inspection

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
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-117
Reassembly
1) Install new oil pump body oil seal (1).
Use special tool and hammer to install it, and then
apply grease to its lip portion.
Special tool
(A): 09913–85210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
2) Install driven gear and drive gear to oil pump body
after applying A/T fluid.
3) Install stator shaft assembly to oil pump body and
tighten 8 pump subassembly bolts (1) to
specification.
Tightening torque
Oil pump subassembly bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
4) After applying A/T fluid to new O-ring, install it to oil
pump body.
5) Check drive gear for smooth rotation by using torque
converter (1).Oil Pump Assembly InspectionS6RW0D5106034
1) Check body clearance of driven gear (1).
Push driven gear to one side of oil pump body (2).
Using a feeler gauge, measure clearance between
driven gear and body. If clearance exceeds its
standard value, replace oil pump assembly.
Clearance between oil pump driven gear and oil
pump body
Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.)
2) Check tip clearance of both drive and driven gears.
Using a feeler gauge, measure clearance between
drive and driven gear tips. If clearance exceeds its
standard value, replace oil pump assembly.
Tip clearance between oil pump drive gear and
oil pump driven gear
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
2. Oil pump body
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1, (a)
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1
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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”
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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”
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2. Gear shift and select shaft assembly
2
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1 2, (a)
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Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-35
Gear Shift Shaft ComponentsS6RW0D5206022
5th and Reverse Gear Shift Shafts Disassembly
and Reassembly
S6RW0D5206023
Disassembly
Disassemble component parts by using special tool and
hammer.
Special tool
: 09922–85811
Reassembly
Replace or correct parts as required and assemble
shafts making sure that component parts are in proper
order as shown in figure.
NOTE
Install 2 steel balls (3) in reverse gear shift
arm (1) without fail.

Gear Shift Shaft and Fork InspectionS6RW0D5206024
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds limit of 1.0 mm (0.039 in.).
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Service limit: 1.0 mm (0.039 in.)
2) Insert each gear shift shaft into case and check that
it moves smoothly. If it doesn’t, correct by using
oilstone, reamer or the like.
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1. Low speed gear shift shaft 4. 5th & reverse gear shift guide shaft 7. 5th & reverse gear shift yoke
2. High speed gear shift shaft 5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
3. 5th & reverse gear shift shaft 6. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
2. Spring 6. 5th & reverse gear shift yoke
4. Spring pin 7. 5th & reverse gear shift guide shaft
5. 5th & reverse gear shift shaft
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Downloaded from www.Manualslib.com manuals search engine 5C-3 Clutch:
Repair Instructions
Clutch Pedal InspectionS6RW0D5306001
Cylinder Push Rod Play “a”
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).
Clutch Pedal Free Travel “b”
1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel
“b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.
Clutch Release Margin “c”
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
Clutch release margin
“c”: 25 – 55 mm (0.98 – 2.17 in.)6) If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”.Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS6RW0D5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to the reservoir cap of the brake master
cylinder.
Air Bleeding of Clutch SystemS6RW0D5306003
CAUTION!
When operating the pedal stroke for air
bleeding of clutch system, after releasing the
clutch pedal, be sure to wait 1 second or
more before depressing it again. Otherwise,
the oil seal of operating cylinder will be
damaged, resulting in oil leakage.

Bleed air from clutch system.
Refer to “Air Bleeding of Brake System in Section 4A”.
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