2006 SUZUKI SX4 length

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-12
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Remove reservoir connector pin (1) by using special
tool and then reservoir.
Special tool
(A): 09916–44310
Installation
1) When using new grommets (2), lubricate them with
the same fluid as the one to fill reservoir with.
Then press-fit grommets (2) to master cylinder (3).
2) Install reservoir (1) to master cylinder.
3) Drive in reservoir connector pin (2) by using special
tool (A). Till both of its ends at the right and left of
reservoir (1) becomes the same length.
Special tool
(A): 09916–44310 4) Connect clutch reservoir hose to reservoir (M/T
model).
5) Connect fluid level switch coupler (1) and clamp (3)
to reservoir (2).
6) Fill reservoir with specified brake fluid up to its MAX
level.
7) After completing the work, bleed air from brake
system referring to “Air Bleeding of Brake System”
and bleed air from clutch system referring to“Air
Bleeding of Clutch System in Section 5C” (M/T
model).
8) Check each installed parts for fluid leakage.
9) Perform brake test and check fluid leakage.
Master Cylinder Removal and InstallationS6RW0D4106012
Removal
CAUTION!
• Never disassemble master cylinder since
the master cylinder is supplied as
assembly parts.
If faulty condition is found, replace it with
new one.
• Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be
damaged by brake fluid, flush it with water
immediately if any fluid is spilled.

1) Clean outside of master cylinder.
2) Disconnect fluid level switch coupler (1) and clamp
(3) from reservoir (2).
1 (A)I5JB0A410013-02
1
2
2
3
I7RW01410010-02
I7RW01410011-01
2
13
I7RW01410009-01
2
13
I7RW01410009-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-16
Booster Push Clevis Rod AdjustmentS6RW0D4106017
Install push clevis rod (1) so that measurement “a” is
obtained and torque nut (2) to specification.
Tightening torque
Clevis pin lock nut (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
Clevis installing position (length “a”)
“a”: 129.5 - 130.5 mm (5.10 - 5.13 in.)
Specifications
Tightening Torque SpecificationsS6RW0D4107001
NOTE
The specified tightening torque is also described in the following.
“Front Brake Hose / Pipe Construction”
“Rear Brake Hose / Pipe Construction”
“Brake Pedal Components”
“Master Cylinder and Brake Booster 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 MaterialS6RW0D4108001
NOTE
Required service material is also described in the following.
“Master Cylinder and Brake Booster Components”

Special ToolS6RW0D4108002
IYSQ01410050-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Front brake caliper bleeder plug 9 0.9 6.5)
Rear wheel cylinder bleeder plug 8 0.8 6.0)
Flexible hose joint bolt 23 2.3 17.0)
Master cylinder fixing nut 18 1.8 13.0)
Brake pipe flare nut 16 1.6 11.5)
Booster mounting nut 13 1.3 9.5)
Clevis pin lock nut 26 2.6 19.0)
09916–44310
Valve guide remover (5 mm)
) / )

Downloaded from www.Manualslib.com manuals search engine 5A-114 Automatic Transmission/Transaxle:
67) Using special tools and hydraulic press, remove
planetary ring gear subassembly (1).
CAUTION!
Do not reuse planetary ring gear
subassembly. Otherwise it may cause
damage to planetary gear unit and/or
reduction gears.

Special tool
(A): 09913–84510
(B): 09923–78210
68) Remove parking lock pawl shaft, then spring (2) and
parking lock pawl (1).69) Screwing 3 bolts (1), remove reduction drive gear
(2).
CAUTION!
Screw 3 bolts into reduction drive gear
uniformly, or reduction drive gear, bearing
and transaxle case may be damaged.

Bolt length
30 mm (1.20 in.)
70) Blowing compressed air from oil hole (1) of oil pump,
remove 1st and reverse brake piston (2).
I2RH0B510138-01
I2RH0B510139-01
I2RH0B510140-01
12I4RS0A510040-01

Downloaded from www.Manualslib.com manuals search engine 5A-122 Automatic Transmission/Transaxle:
Direct Clutch Assembly InspectionS6RW0D5106038
Clutch Discs, Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated, discolored,
replace all discs.
• Before assembling new discs, soak them
in A/T fluid for at least two hours.

Direct Clutch Return Spring Subassembly
Measure free length of direct clutch return spring
subassembly.
Direct clutch return spring subassembly free length
“a”: 36.04 mm (1.419 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Direct Clutch Piston
Shake direct clutch piston lightly and check that check
ball (1) is not stuck.
Blow in low pressure air (Max. 100 kPa, 1 kg/cm
2, 15 psi)
to check ball to check that there is no leakage.
I2RH0B510172-01
I2RH0B510173-01
I2RH0B510174-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-127
• Install reverse clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
• Measure reverse clutch piston stroke in the same
manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
reverse clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
Available reverse clutch retaining plate thickness
Forward and Reverse Clutch Assembly
Inspection
S6RW0D5106042
Clutch, Discs, Separator Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
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.

Forward Clutch Return Spring Subassembly
Measure free length of forward clutch return spring.
Forward clutch return spring free length
24.04 mm (0.946 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

[A]: Correct [B]: Incorrect
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
3.6 mm (0.142 in.) 4
I2RH0B510190-01
I2RH0B510191-01
I2RH0B510192-01
I2RH0B510193-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-131
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal rings and O-rings. Apply A/T fluid to
seal rings and O-rings before installation.
• Tighten rear cover plugs to specified torque.
Tightening torque
Rear cover plug: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
• Before installing rear cover seal ring, apply A/T fluid to
ring.
First, tighten seal ring to 5 mm (0.197 in.), then install
seal ring.
• Do not open rear cover seal ring too wide to attach.
• Do not damage O/D and 2nd coast brake return
spring subassembly and piston by pressing in O/D
and 2nd coast brake return spring subassembly
passing through its original installing position over 1.0
mm (0.039 in.).
Special tool
(A): 09926–96030
(B): 09946–06710Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Inspection
S6RW0D5106047
O/D and 2nd Coast Brake Return Spring
Subassembly
Measure free length of O/D and 2nd coast brake return
spring subassembly.
Free length of O/D and 2nd coast brake return spring
subassembly
“a”: 18.99 mm (0.748 in.)
NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.

Transaxle Rear Cover Bush
Measure transaxle rear cover bush bore by using special
tool.
If measured transaxle rear cover bush bore is out of
specifications, replace transaxle rear cover with new
one. In replacement, intermediate shaft subassembly
also needs to be checked. Replace intermediate shaft
subassembly, if necessary.
Special tool
(A): 09900–20605
Transaxle rear cover bush bore
Standard: 13.94 – 13.96 mm (0.549 – 0.550 in.)
1. Transaxle rear cover
1. Transaxle rear cover
I2RH0B510206-01
I2RH0B510201-01
I2RH0B510207-01
I2RH0B510208-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-135
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Shift solenoid valve-A and -B are identical
• After applying A/T fluid to new O-rings, fit them to
solenoid valves, then install solenoid valves to valve
body.
• Tighten solenoid valve bolts to specified torque
Tightening torque
Solenoid valve bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Solenoid valve bolt specification
Differential Assembly ComponentsS6RW0D5106052
Bolt Length “a” Pieces
A (1) 49 mm (1.93 in.) 5
B (2) 20 mm (0.79 in.) 1
C (3) 60 mm (2.36 in.) 1
1
1 1
3
2
"a"
I4RS0A510046-01
I5RW0C510064-01
1. Differential side RH bearing 5. Side bearing shim : Apply automatic transaxle fluid.
2. Output shaft speed sensor (VSS) drive gear 6. Final gear bolt : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
3. Differential case subassembly 7. Side bearing cup : Do not reuse.
4. Final gear 8. Differential side LH bearing

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