2006 SUZUKI SX4 section 1a

Downloaded from www.Manualslib.com manuals search engine 5A-152 Automatic Transmission/Transaxle:
43) Measure O/D and 2nd coast brake piston stroke.
• Measure dimension “a” from end face of transaxle
case to O/D and 2nd coast brake rear plate (1)
using straightedge and micrometer caliper.
• Measure dimension “b” from O/D and 2nd coast
brake piston (2) to rear cover assembly mating
surface using straightedge and micrometer
caliper.
• Calculate piston stroke from measured value of
dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.)
When piston stroke is out of specification, select O/D
and 2nd coast brake rear plate with proper thickness
from among the following table and replace it.
CAUTION!
When brake disc, retaining plate, separator
plate and/or rear plate of O/D and 2nd coast
brake have been replaced, all learned
contents, which have been stored in TCM
memory by executing learning control,
should be initialized referring to “Learning
Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

Available O/D and 2nd coast brake rear plate
thickness
44) After applying A/T fluid to new 2nd brake gaskets (1),
install them to transaxle case (2).
45) After applying A/T fluid to reverse clutch drum thrust
bearing (1), install it to forward and reverse clutch
assembly (2).
46) Remove sealant attached to mating surface of
transaxle rear cover (1) completely.
47) Apply sealant to mating surface of transaxle rear
cover (1) by using a nozzle (2) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B) Thickness Identification mark
1.8 mm (0.071 in.) 1
2.0 mm (0.079 in.) 2
2.2 mm (0.087 in.) 3
2.4 mm (0.094 in.) 4
2.6 mm (0.102 in.) 5
I2RH0B510298-01
I2RH0B510299-01
I2RH0B510300-01
“A”2
1
I2RH0B510301-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-155
61) Measure input shaft thrust play.
Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
When input shaft thrust play is out of specification,
select input shaft front thrust bearing with proper
thickness from among the following table and
replace it.
Available input shaft front thrust bearing
thickness
62) After applying A/T fluid to new O-ring, fit it to
breather union (2). Then install breather union to
transaxle case.
63) Install breather hose (1).
64) Wipe off and clean mating surface between
transaxle case (1) and torque converter housing.
65) Apply sealant to torque converter housing by using a
nozzle (2) as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)66) Install torque converter housing to transaxle case,
tighten bolts to specified torque.
CAUTION!
Apply sealant to threads of four bolts shown
in figure before tightening.

“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Tightening torque
Torque converter housing bolt (a): 33 N·m (3.3
kgf-m, 24.0 lb-ft)
67) After applying A/T fluid to new O-ring, fit it to
transaxle case plug (1). Then install the transaxle
case plug to transaxle case (2).
Tightening torque
Transaxle case plug (a): 7.5 N·m (0.75 kgf-m, 5.5
lb-ft) ThicknessOutside
diameterInside diameter
3.45 mm
(0.14 in.)48.5 mm
(1.90 in.)32.9 mm
(1.30 in.)
4.05 mm
(0.16 in.)48.5 mm
(1.90 in.)32.5 mm
(1.28 in.)
I2RH0B510313-01
I2RH0B510314-01
12
“A”
I2RH0B510315-01
I3RM0B510069-01
I2RH0B510317-01

Downloaded from www.Manualslib.com manuals search engine 5A-156 Automatic Transmission/Transaxle:
68) Install new O-rings to each accumulator piston and
apply A/T fluid to them.
Accumulator O-ring dimension
NOTE
Make sure that O-rings are not twisted or
caught when installing.

69) Install B1, C1, C2 accumulator pistons and springs.
Accumulator piston identification
Accumulator spring identification
70) After applying A/T fluid to cooler check valve (1) and
spring (2), install them to transaxle case (3).
71) After applying A/T fluid to new governor apply No.1
gasket (1), install it to transaxle case. O-ring nameInside
diameterSection
diameter
Large B1 accumulator O-ring (2)
Large C1 accumulator O-ring (2)
Large C2 accumulator O-ring (2)
– Above three O-rings are same.29.4 mm
(1.16 in.)2.6 mm
(0.10 in.)
Small B1 accumulator O-ring (4)19.7 mm
(0.78 in.)2.6 mm
(0.10 in.)
Small C1 accumulator O-ring (6)
Small C2 accumulator O-ring (6)
– Above two O-rings are same.21.8 mm
(0.86 in.)2.6 mm
(0.10 in.)
Piston nameIdentification as
embossed letters on
piston
B1 accumulator piston (3) SB-1
C1 accumulator piston (5) SC-1
C2 accumulator piston (8) SC-2
Spring nameColor of identification
paint
B1 accumulator No.2
spring (1)Pink
C1 accumulator No.2
spring (7)Blue
C2 accumulator No.2
spring (9)Light green
I2RH0B510318-01
I2RH0B510319-01
I2RH0B510320-01

Downloaded from www.Manualslib.com manuals search engine 5A-160 Automatic Transmission/Transaxle:
94) Install manual select lever (1).
Tightening torque
Manual select lever nut (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
95) Install engine mounting LH bracket (1). Tighten
engine mounting LH bracket bolts and nut to
specified torque referring to “Engine Mountings
Components in Section 1D”.
96) Install torque converter (3) noting the following
points.
CAUTION!
• Before installing converter, make sure that
its pump hub portion is free from nicks,
burrs or damage which may cause oil seal
to leak.
• Be very careful not to drop converter on oil
pump gear. Damage in gear, should it
occur, may cause a critical trouble.

• Install torque converter aligning grooves (1) of
torque converter and projection (2) of oil pump
drive gear.
• Install torque converter, using care not to damage
oil seal of oil pump.
• After installing torque converter, check that
distance “a” is within specification.
Torque converter installing position
“a”: More than 19.9 mm (0.783 in.)
• Check torque converter for smooth rotation.
• Apply grease around cup (6) at the center of
torque converter.
“C”: Grease 99000–25011 (SUZUKI Super
Grease A)
1(a)I2RH0B510335-01
1
I5RW0C510058-01
4. Flange nut
5. Torque converter housing
I2RH0B510337-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-161
Specifications
Tightening Torque SpecificationsS6RW0D5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
A/T fluid drain plug 17 1.7 12.5) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor (VSS) bolt 13 1.3 9.5) / )
Input shaft speed sensor bolt 5.5 0.55 4.0) / )
Valve body harness connector bolt 5.5 0.55 4.0) / )
Shift solenoid bolt 11 1.1 8.0)
Oil strainer bolt 10 1.0 7.5) / )
Oil pan bolt 7.0 0.7 5.0) / )
Engine oil pan bolt 55 5.5 40.0)
Transaxle and engine fastening bolt 85 8.5 61.5)
Transaxle and engine fastening nut 85 8.5 61.5)
Drive plate to torque converter bolt 19 1.9 14.0)
Transaxle housing lower plate bolt 11 1.1 8.0)
Oil pump subassembly bolt 10 1.0 7.5)
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 11 1.1 8.0)
Final gear bolt 78 7.8 56.5)
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 33 3.3 24.0) / ) / )
Manual detent spring bolt 10 1.0 7.5)
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 25 2.5 18.0)
Fluid reservoir LH plate bolt 10 1.0 7.5)
Oil pump assembly bolt 25 2.5 18.0)
Transaxle case plug 7.5 0.75 5.5)
Valve body bolt 11 1.1 8.0)
Fluid cooler pipe union 25 2.5 18.0)
Fluid cooler pipe union bolt 35 3.5 25.5)
Fluid cooler pipe bracket bolt 10 1.0 7.5)
Fluid filler tube bolt 10 1.0 7.5)
Select cable bracket bolt 23 2.3 17.0)
Select cable clamp bolt 13 1.3 9.5)
Transmission range sensor lock nut 7 0.7 5.0)
Manual select lever nut 13 1.3 9.5)

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-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-14 Manual Transmission/Transaxle:
Gear Shift and Select Shaft Assembly Removal
and Installation
S6RW0D5206012
Removal
1) Remove battery and tray with ECM.
2) Disconnect gear shift and gear select control cables
from transaxle.
3) Remove gear shift interlock bolt (1) and 5th to
reverse interlock guide bolt (2) from transaxle case.
4) Remove gear shift & select shaft assembly (3).
Installation
1) Clean mating surface of guide case (1) and left case
(5), apply sealant to left case as shown in figure by
such amount that its section is 1.5 mm (0.059 in.) in
diameter, mate guide case with left case.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
2) Install guide case bolts No.1 to which sealant has
been applied and guide case bolts No.2 (2), and
tighten them to specified torque.
: Sealant 99000–31260 (SUZUKI Bond No.1217G)
Tightening torque
Guide case bolt No.1: 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
Guide case bolt No.2 (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)3) Install washer and gear shift interlock bolt (3) to
which sealant has been applied and then tighten it to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift interlock bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
4) Install washer and 5th to reverse interlock guide bolt
(4) to which sealant has been applied and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
5th to reverse interlock guide bolt (c): 23 N·m (
2.3 kgf-m, 17.0 lb-ft)
5) Connect gear shift and gear select control cables to
transaxle.
6) Install battery and tray with ECM.
7) Check input shaft for rotation in each gear position.
4. Transaxle side cover
3
1
2
4
I5RW0A520016-01
I5RW0A520017-02