2006 SUZUKI SX4 Transmission removal

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Gear Shift Control Lever and Cable Removal
and Installation
S6RW0D5206005
Removal
1) Remove console box.
2) Disconnect cable ends (5) from pivot (6) of gear shift
control lever assembly by removing clip.
3) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly (2) while
pulling quick joint (4) as shown in figure.
4) Remove gear shift control lever assembly mounting
nuts (3) and gear shift lever assembly from floor
panel.
5) Disconnect gear shift and select control cables from
transaxle.
6) Remove cable grommet bolt, and then remove gear
shift and select control cables from floor panel.
Installation
Reverse removal procedure for installation nothing the
following.
• Tighten each bolts and nuts to specified torque
referring to “Gear Shift Control Lever and Cable
Components”.
• Adjust gear select control cable referring to “Gear
Select Control Cable Adjustment”.
Gear Select Control Cable AdjustmentS6RW0D5206006
1) Release lock plate (1) which restricts moving of
cable end holder (2).
2) Push cable end holder (2) out from adjuster (4) using
appropriate tool (3) to disengage cable.
36
5
2
3
41
I4RS0A520003-01
I4RS0A520004-01

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-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

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-20 Manual Transmission/Transaxle:
2) Remove bearing set shim.
3) Remove snap ring (1) using special tool.
Special tool
(A): 09900–06107
4) Remove gear shift locating bolts (1), then take out
locating springs and steel balls.
5) Remove reverse shaft bolt (2) with washer.
6) Remove transaxle case bolts (1) from outside and
another bolts from clutch housing side.
7) Tapping left case flanges with plastic hammer,
remove left case.8) Pull out reverse gear shaft (1) with washer (2), then
take off reverse idler gear (3).
9) Remove reverse gear shift lever bolts (4) and
reverse gear shift lever (5).
10) Pull out 5th & reverse gear shift guide shaft (6)
together with 5th & reverse gear shift shaft (7).
NOTE
When removing 5th & reverse gear shift shaft
(7) and guide shaft (6), push up high speed
gear shift shaft and shift it to 4th to facilitate
removal of 5th & reverse shift shaft.

11) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, then take out
input shaft assembly (1), countershaft assembly (2),
high speed gear shift shaft (3) and low speed gear
shift shaft (4) all at once.
12) Remove countershaft left bearing outer race from left
case.
13) Remove differential assembly from right case.
2. Input shaft
3. Input shaft left bearing
1 (A)
2
3
I4RH01520019-01
1I5RW0A520021-01
I4RH01520020-01
I3RH0A520012-01
I2RH01520035-01

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

Downloaded from www.Manualslib.com manuals search engine 5B-28 Manual Transmission/Transaxle:
Input Shaft Disassembly and ReassemblyS6RW0D5206020
Disassembly
1) Remove input shaft right bearing (2) from input shaft
(1) using bearing puller (3) and hydraulic press.
2) Drive out 5th gear spacer (2), left bearing (3) and 4th
gear (4) all at once using puller (5) and hydraulic
press.
CAUTION!
• To avoid gear tooth from being damaged,
support it at flat side of bearing puller.
• Stop press work in the middle way and
take out 5th gear bush to prevent it from
being compressed and then continue to
remove bearing with gear.

3) Take out 4th gear needle bearing and high speed
synchronizer ring.
4) Using special tool, remove circlip (1).
NOTE
For smooth removal of circlip, it is
recommended to correct tool tips to be flat.

Special tool
(A): 09900–06107
5) Drive out high speed synchronizer sleeve & hub
assembly (2) together with 3rd gear (3) by using
puller (4) and hydraulic press.
CAUTION!
To avoid gear tooth from being damaged,
support it at flat side of bearing puller.

6) Take out 3rd gear needle bearing from input shaft.
7) Disassemble synchronizer sleeve & hub assembly.
1. Input shaft
I4RH01520029-01
I3RH0A520018-011. Input shaft
I2RH01520046-01
I2RH01520097-01