2006 SUZUKI SX4 brake drum

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-6
Installation
Install brake back plate by reversing removal procedure,
noting the instructions.
CAUTION!
Never reuse rear wheel hub mounting bolts.

• Install rear wheel hub and brake back plate, and then
tighten mounting bolt. Refer to “Rear Drum Brake
Components”.
• Install parking brake cable (1) to brake back plate.
Tightening torque
Parking cable cap nut (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)• After installing all removed parts, bleed air from brake
system referring to “Air Bleeding of Brake System in
Section 4A”. and then adjust parking brake cable
referring to “Parking Brake Inspection and Adjustment
in Section 4D”.
Specifications
Tightening Torque SpecificationsS6RW0D4307001
NOTE
The specified tightening torque is also described in the following.
“Rear Drum Brake Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D4308001
NOTE
Required service material is also described in the following.
“Rear Drum Brake Components”

1
(a)
I4RS0A430024-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Wheel cylinder mounting bolt 12 1.2 9.0)
Rear brake pipe flare nut 16 1.6 11.5)
Parking cable cap nut 11 1.1 8.0)

Downloaded from www.Manualslib.com manuals search engine Parking Brake: 4D-2
Repair Instructions
Parking Brake Inspection and AdjustmentS6RW0D4406001
Inspection
Hold center of parking brake lever grip and pull it up with
200 N (20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count
ratchet notches. There should be 4 – 9 notches.
Also, check if both right and left rear wheels are locked
firmly.
To count number of notches easily, listen to click sounds
that ratchet makes while pulling parking brake lever
without pressing its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable
referring to adjustment procedure so as to obtain
specified parking brake stroke.
NOTE
Check tooth tip of each notch for damage or
wear.
If any damage or wear is found, replace
parking brake lever.

Adjustment
NOTE
Make sure for the following conditions before
cable adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Start engine and then brake pedal has
been depressed at least 3 times with about
300 N (30 kg, 66 lbs) load.
• Parking brake lever has been pulled up a
few times with about 200 N (20 kg, 44 lbs)
load.
If parking brake cable is replaced with new
one, pull up parking brake lever a few
times with about 500 N⋅m (50 kg, 110 lbs)
force.

After confirming that the conditions are all satisfied,
adjust parking brake lever stroke by loosening or
tightening adjust nut (1).
NOTE
Check brake drum for dragging after
adjustment.

Parking brake stroke
When lever is pulled up at 200 N (20 kg, 44 lbs): 4 to
9 notches
Parking Brake Cable Removal and InstallationS6RW0D4406002
Removal
NOTE
When it is necessary to remove both right
and left parking brake cables, repeat below
steps 2) and 6) on right and left wheels.

1) Hoist vehicle.
2) Remove wheel.
3) Disconnect parking brake cable from equalizer
(parking brake lever) and clamps.
4) Remove brake drum. Refer to “Rear Brake Drum
Removal and Installation in Section 4C”.
5) Disconnect parking brake cable from brake shoe
lever referring to “Rear Brake Shoe Removal and
Installation in Section 4C”.
6) Remove parking brake cable and parking cable
bracket.
Installation
Install it by reversing removal procedure, noting the
following points.
• Install clamps properly referring to “Parking Brake
Cable Construction”.
• Tighten bolts and nuts to specified torque referring to
“Parking Brake Cable Construction”.
• Adjust parking brake cable. Refer to “Parking Brake
Inspection and Adjustment”.
• Check brake drum for dragging and brake system for
proper performance. Brake test should be performed.
I4RS0B440002-01
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I6RW0C440002-01

Downloaded from www.Manualslib.com manuals search engine 4D-3 Parking Brake:
Parking Brake Lever Removal and InstallationS6RW0D4406003
Removal
1) Remove console box.
2) Block vehicle wheels and release parking brake
lever.
3) Disconnect lead wire of parking brake switch at
coupler.
4) Loosen parking brake cable adjusting nut (1).
5) Remove parking brake lever bolts (1) and then
remove parking brake lever assembly (2) with
equalizer (3).
NOTE
Don’t disassemble parking brake lever
switch. It must be removed and installed as a
complete switch assembly.

Installation
1) Install in reverse order of removal procedure.
Check equalizer inclined angle.
Tightening torque
Parking brake lever bolt (a): 26 N·m (2.6 kgf-m,
19.0 lb-ft)
2) After all parts are installed, parking brake lever
needs to be adjusted. Refer to “Parking Brake
Inspection and Adjustment”.
3) Check brake drum for dragging and brake system for
proper performance. After removing vehicle from
hoist, brake test should be performed.
I4RS0A440004-01
I5RW0A440002-01
I5RW0A440003-01

Downloaded from www.Manualslib.com manuals search engine 5A-4 Automatic Transmission/Transaxle:
I5RW0C510070-01
1. Drive plate 11. 1st and reverse brake 21. Rear sun gear
2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear
3. Torque converter 13. Long planet pinion 23. Short planet pinion
4. Input shaft 14. One-way No.2 clutch 24. Countershaft
5. Oil pump 15. 2nd brake 25. Reduction driven gear
6. Direct clutch drum (double as sensor rotor for input shaft
speed sensor)16. One-way No.1 clutch 26. Differential case assembly
7. Direct clutch 17. O/D and 2nd coast brake 27. Final gear
8. Parking lock gear 18. Intermediate shaft 28. Output shaft speed sensor (VSS) drive gear
9. Reduction drive gear 19. Forward clutch
10. Planet carrier 20. Reverse clutch

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-112 Automatic Transmission/Transaxle:
53) Remove 2nd brake piston assembly (1).
54) Remove 2nd brake return spring subassembly (2).
55) Remove 2nd brake separator plates (1), discs (2)
and retaining plate (3).
56) Remove brake drum gasket (1).
57) Remove one-way clutch outer race retainer (1).58) Check one-way clutch No.2 as follows.
• Ensure planetary carrier (1) rotates only in
counterclockwise direction “A”, never in clockwise
direction “B”.
• If the planetary carrier rotates both ways or does
not rotate either way, one-way clutch No.2
assembly will need to be replaced with new one-
way clutch No.2 assembly.
59) Remove one-way clutch No.2 assembly (1).
60) Remove planetary gear assembly (1).
1
2
I4RS0A510038-01
I2RH0B510127-01
I2RH0B510128-01
I2RH0B510129-01
I2RH0B510130-01
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I4RS0A510039-01
I2RH0B510132-01

Downloaded from www.Manualslib.com manuals search engine 5A-128 Automatic Transmission/Transaxle:
Forward Clutch Piston Lip and Forward Clutch
Balancer Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.Forward Clutch Drum Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
2nd Brake Piston Assembly ComponentsS6RW0D5106043
2nd Brake Piston Assembly Disassembly and
Reassembly
S6RW0D5106044
Disassembly
1) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of 2nd brake cylinder (3)
to remove 2nd brake piston (2).
I2RH0B510194-01
I2RH0B510195-01
I2RH0B510196-01
1. 2nd brake cylinder 4. Outer O-ring
2. 2nd brake piston : Apply automatic transaxle fluid.
3. Inner O-ring : Do not reuse.
I2RH0B510197-01

Downloaded from www.Manualslib.com manuals search engine 5A-148 Automatic Transmission/Transaxle:
20) Check for correct installation of planetary gear
assembly as follows.
Measure the distance “a” by using micrometer
caliper (1) and straightedge (2). If measured value is
out of specification, remove planetary gear assembly
and reinstall it properly.
Distance between planetary gear assembly and
mating surface of transaxle case
“a”: More than 49.9 m (1.965 in.)
21) Apply A/T fluid to one-way clutch No.2 assembly (1),
then install it to planetary gear assembly. After that,
ensure that planetary carrier rotates only in
counterclockwise direction “A”, not in clockwise
direction “B”.22) Install one-way clutch outer race retainer (1).
23) Apply A/T fluid to new brake drum gasket (1), then
install it to transaxle case.
24) Apply A/T fluid to 2nd brake retaining plate (1), discs
(2) and separator plates (3), then install them to
transaxle case.
25) Install 2nd brake return spring subassembly (1) to
transaxle case.
“a”
“a”
2
1
I2RH0B510276-01
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I2RH0B510278-01
I2RH0B510279-01
2
3
1
I2RH0B510280-01
1
I2RH0B510281-01