2006 SUZUKI SX4 check engine

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-36
Installation
1) Check that no foreign material is attached to sensor
(1) and wheel speed sensor encoder (included in
wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Front wheel speed sensor harness clamp bolt
(b): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and knuckle.
Front and Rear Wheel Speed Sensor InspectionS6RW0D4506007
Check sensor for damage.
If any malcondition is found, replace.
Rear Wheel Speed Sensor Removal and
Installation (4WD Model)
S6RW0D4506008
CAUTION!
Rear wheel speed sensor is included in rear
wheel hub assembly. If rear wheel speed
sensor needs to be replaced, replace it as a
rear wheel hub assembly.

For removal and Installation of rear wheel speed sensor
(included in rear wheel hub), refer to “Rear Wheel Hub
Assembly Removal and Installation in Section 2C”.
Rear Wheel Speed Sensor Removal and
Installation (2WD Model)
S6RW0D4506009
CAUTION!
• Do not pull wire harness when removing
and installing rear wheel speed sensor.
• Do not cause damage to surface of rear
wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle, and remove wheel.
3) Disconnect rear wheel speed sensor connector.
4) Remove harness clamp.
5) Remove rear wheel speed sensor from wheel hub.
Installation
1) Check that no foreign material is attached to sensor
and encoder (included in wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Rear wheel speed sensor bolt: 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and wheel hub.[A]: OK [B]: NG
1
2
(b)
(a)
I5RW0A450025-01
[A][B]
11
I5RW0A450024-01
I5JB0A450031-01
[A]: OK [B]: NG
[A][B]
11
I5RW0A450024-01

Downloaded from www.Manualslib.com manuals search engine 4E-37 ABS:
Front Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506010
Before inspecting front wheel speed sensor encoder,
remove front drive shaft referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check sensor encoder (1) for crack, damage or
deformation.
• Turn wheel and check if sensor encoder rotation is
free from eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Front
Wheel Hub, Steering Knuckle and Wheel Bearing
Removal and Installation in Section 2B”.
Front Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506011
CAUTION!
Front wheel speed sensor encoder is
included in front wheel hub assembly. If front
wheel speed sensor encoder needs to be
replaced, replace it as a front wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Front Wheel Hub, Steering
Knuckle and Wheel Bearing Removal and Installation in
Section 2B”.
Rear Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506012
For 4WD model
Refer to “Rear Wheel Speed Sensor On-Vehicle
Inspection”.
For 2WD model
Before inspecting rear wheel speed sensor encoder,
remove rear wheel speed sensor referring to “Rear
Wheel Speed Sensor Removal and Installation (2WD
Model)”.
• Check encoder (1) for crack, damage or deformation.
• Turn wheel and check if encoder rotation is free from
eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Rear
Wheel Hub Assembly Removal and Installation in
Section 2C”.
Rear Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506013
CAUTION!
Rear wheel speed sensor encoder is included
in rear wheel hub assembly. If rear wheel
speed sensor encoder needs to be replaced,
replace it as a rear wheel hub assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Assembly
Removal and Installation in Section 2C”.
1
I5RW0A450026-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-38
G Sensor Removal and Installation (4WD Model)S6RW0D4506014
CAUTION!
• Do not drop and shock G sensor. It will
affect its original performance.
• Regarding G sensor removal and
installation, confirm specified torque and
use hand tool to avoid damage.

Removal
1) Disconnect negative (–) cable from battery.
2) Remove center console box.
3) Disconnect G sensor connector, and remove G
sensor (1).
Installation
1) Install G sensor (1), and connect G sensor
connector.
Tightening torque
G sensor bolt (a): 3.0 N·m (0.3 kgf-m, 2.2 lb-ft)
2) Install center console box.
3) Connect negative cable to battery.
G Sensor Inspection (4WD Model)S6RW0D4506015
Connect positive cable of 12 V battery to “A” terminal of
sensor and ground cable to “C” terminal.
Then using voltmeter, check voltage between terminals
“B” and “C”.
If measured voltage is not as specified, replace G
sensor.
G sensor specification
When placed horizontally: 2 – 3 V
When placed upright with arrow upward: 3 – 4 V
When placed upright with arrow downward: 1 – 2 V
I5RW0A450027-01
I5RW0A450028-01
[A]: Horizontal [C]: Upright with arrow downward
[B]: Upright with arrow upward
I5RW0A450029-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1
Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and
Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3
A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of
Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
A/T Diagnosis General Description ..................... 5A-7
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10
Transmission Control Module (TCM) Wiring
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Location ......................................... 5A-14
Electronic Shift Control System Components
Location .......................................................... 5A-14
Diagnostic Information and Procedures .......... 5A-16
A/T System Check ............................................ 5A-16
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-19
Transmission Warning Light Check (Non-
Euro-OBD model) ........................................... 5A-19
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-21
DTC Clearance ................................................. 5A-22
Fail-Safe Table .................................................. 5A-22
Scan Tool Data ................................................. 5A-24
A/T Basic Check ............................................... 5A-27
Road Test ......................................................... 5A-27
Manual Road Test ............................................. 5A-30
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-31
Time Lag Test ................................................... 5A-32
Line Pressure Test ............................................ 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ................................... 5A-34Transmission Warning Light Circuit Check –
Light Remains “ON” at Ignition Switch ON
(Non-Euro-OBD Model)................................... 5A-41
Transmission Warning Light Circuit Check –
Light Does Not Come “ON” at Ignition Switch
ON (Non-Euro-OBD Model)............................ 5A-41
DTC P0602: Control Module Programming
Error ................................................................ 5A-42
DTC P0705: Transmission Range Sensor
Circuit Malfunction (PRNDL Input) .................. 5A-42
DTC P0707: Transmission Range Sensor
Circuit Low ...................................................... 5A-44
DTC P0711: Transmission Fluid Temperature
Sensor “A” Control Range / Performance ....... 5A-46
DTC P0712: Transmission Fluid Temperature
Sensor Circuit Low .......................................... 5A-47
DTC P0713: Transmission Fluid Temperature
Sensor Circuit High ......................................... 5A-48
DTC P0717: Input / Turbine Speed Sensor
Circuit Malfunction........................................... 5A-50
DTC P0722: Output Speed Sensor (VSS)
Circuit No Signal ............................................. 5A-51
DTC P0741 / P0742: TCC Circuit
Performance or Stuck OFF / TCC Circuit
Stuck ON ......................................................... 5A-53
DTC P0751 / P0752 / P0756 / P0757: Shift
Solenoid Malfunction ....................................... 5A-54
DTC P0787: Shift / Timing Solenoid Control
Circuit Low ...................................................... 5A-55
DTC P0788: Shift / Timing Solenoid Control
Circuit High...................................................... 5A-57
DTC P0961: Pressure Control Solenoid “A”
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure Control Solenoid
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure Control Solenoid
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid-A (No.1)
Control Circuit Low / Shift Solenoid-B (No.2)
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid-A (No.1)
/ Shift Solenoid-B (No.2) Control Circuit High .. 5A-66
DTC P1702: Internal Control Module Memory
Check Sum Error............................................. 5A-68

Downloaded from www.Manualslib.com manuals search engine 5-ii Table of Contents
DTC P1723: Range Select Switch
Malfunction ...................................................... 5A-68
DTC P1878: Torque Converter Clutch
Shudder .......................................................... 5A-69
DTC P2762: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
Range / Performance ...................................... 5A-70
DTC P2763: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
High ................................................................. 5A-72
DTC P2764: Torque Converter Clutch (TCC)
Circuit Pressure Control Solenoid Control
Circuit Low ...................................................... 5A-74
DTC U0073: Control Module Communication
Bus Off ............................................................ 5A-76
DTC U0100: Lost Communication with ECM /
PCM “A” .......................................................... 5A-76
Inspection of TCM and Its Circuits .................... 5A-76
TCM Power and Ground Circuit Check ............. 5A-80
Brake Interlock System Inspection .................... 5A-81
Repair Instructions ............................................5A-82
Learning Control Initialization ............................ 5A-82
A/T Fluid Level Check ....................................... 5A-82
A/T Fluid Change .............................................. 5A-83
Select Lever Components ................................. 5A-84
Select Lever Assembly Removal and
Installation ....................................................... 5A-84
Select Lever Knob Installation........................... 5A-84
Select Lever Inspection ..................................... 5A-85
“3” Position Switch Inspection ........................... 5A-85
Shift Lock Solenoid Inspection .......................... 5A-85
Shift Lock Solenoid Replacement ..................... 5A-85
Select Cable Components ................................ 5A-86
Select Cable Removal and Installation ............. 5A-86
Select Cable Adjustment ................................... 5A-86
Key Interlock Cable Removal and Installation... 5A-87
Transmission Range Sensor Inspection and
Adjustment ...................................................... 5A-89
Output Shaft Speed Sensor (VSS) Removal
and Installation ................................................ 5A-90
Output Shaft Speed Sensor (VSS) Inspection .. 5A-90
Input Shaft Speed Sensor Removal and
Installation ....................................................... 5A-91
Input Shaft Speed Sensor Inspection................ 5A-91
Transmission Fluid Temperature Sensor
Removal and Installation ................................. 5A-91
Transmission Fluid Temperature Sensor
Inspection ........................................................ 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation ....................................................... 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Inspection .................. 5A-94
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid)
Removal and Installation ................................. 5A-95
Pressure Control Solenoid Valves Inspection ... 5A-96
Transmission Control Module (TCM)
Removal and Installation ................................. 5A-97
A/T Relay Inspection ......................................... 5A-97Differential Side Oil Seal Replacement ............. 5A-98
A/T Fluid Cooler Hoses Replacement ............... 5A-98
Automatic Transaxle Unit Components............. 5A-99
Automatic Transaxle Unit Dismounting and
Remounting ................................................... 5A-100
Automatic Transaxle Assembly Components . 5A-102
Automatic Transaxle Unit Disassembly........... 5A-104
Oil Pump Assembly Components ................... 5A-116
Oil Pump Assembly Disassembly and
Reassembly .................................................. 5A-116
Oil Pump Assembly Inspection ....................... 5A-117
Direct Clutch Assembly Components.............. 5A-119
Direct Clutch Assembly Preliminary Check ..... 5A-119
Direct Clutch Assembly Disassembly and
Reassembly .................................................. 5A-120
Direct Clutch Assembly Inspection.................. 5A-122
Forward and Reverse Clutch Assembly
Components .................................................. 5A-123
Forward and Reverse Clutch Assembly
Preliminary Check ......................................... 5A-123
Forward and Reverse Clutch Assembly
Disassembly and Reassembly ...................... 5A-124
Forward and Reverse Clutch Assembly
Inspection ...................................................... 5A-127
2nd Brake Piston Assembly Components ....... 5A-128
2nd Brake Piston Assembly Disassembly and
Reassembly .................................................. 5A-128
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Components........... 5A-129
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Disassembly and
Reassembly .................................................. 5A-130
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Inspection............... 5A-131
Countershaft Assembly Components.............. 5A-132
Countershaft Assembly Disassembly and
Reassembly .................................................. 5A-132
Valve Body Assembly Components ................ 5A-133
Valve Body Assembly Disassembly and
Reassembly .................................................. 5A-134
Differential Assembly Components ................. 5A-135
Differential Assembly Disassembly and
Reassembly .................................................. 5A-136
Differential Assembly Inspection ..................... 5A-137
Torque Converter Housing Disassembly and
Reassembly .................................................. 5A-138
Transaxle Case Disassembly and
Reassembly .................................................. 5A-140
Automatic Transaxle Unit Inspection and
Adjustment .................................................... 5A-141
Automatic Transaxle Unit Assembly ............... 5A-144
Specifications ...................................................5A-161
Tightening Torque Specifications .................... 5A-161
Special Tools and Equipment .........................5A-162
Recommended Service Material ..................... 5A-162
Special Tool .................................................... 5A-162
Manual Transmission/Transaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction .......................... 5B-1

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Diagnostic Information and Procedures ............ 5B-5
Manual Transaxle Symptom Diagnosis............... 5B-5
Repair Instructions .............................................. 5B-5
Manual Transaxle Oil Level Check ..................... 5B-5
Manual Transaxle Oil Change ............................ 5B-6
Differential Side Oil Seal Replacement ............... 5B-7
Gear Shift Control Lever and Cable
Components...................................................... 5B-8
Gear Shift Control Lever and Cable Removal
and Installation .................................................. 5B-9
Gear Select Control Cable Adjustment ............... 5B-9
Back Up Light Switch Removal and
Installation ....................................................... 5B-10
Back Up Light Switch Inspection ....................... 5B-10
Manual Transaxle Unit Components ................. 5B-11
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-12
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-13
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-14
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly ........................ 5B-15
Manual Transaxle Assembly Components........ 5B-16
Fifth Gear Disassembly and Reassembly ......... 5B-17
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-19
Right Case Disassembly and Reassembly ....... 5B-24
Left Case Disassembly and Reassembly.......... 5B-25
Input Shaft and Countershaft Components....... 5B-27
Input Shaft Disassembly and Reassembly........ 5B-28
Countershaft Disassembly and Reassembly .... 5B-31
Gear Shift Shaft Components ........................... 5B-35
5th and Reverse Gear Shift Shafts
Disassembly and Reassembly ........................ 5B-35
Gear Shift Shaft and Fork Inspection ................ 5B-35
Differential Components ................................... 5B-36Differential Disassembly and Reassembly ........ 5B-36
Specifications .....................................................5B-38
Tightening Torque Specifications ...................... 5B-38
Special Tools and Equipment ...........................5B-39
Recommended Service Material ....................... 5B-39
Special Tool ...................................................... 5B-39
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch (Hydraulic Type) Construction .................5C-1
Diagnostic Information and Procedures ............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-3
Clutch Pedal Inspection ......................................5C-3
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Fluid Pipe and Hose Location ..................5C-4
Clutch Fluid Pipe Removal and Installation.........5C-4
Clutch Fluid Pipe Inspection................................5C-4
Clutch Master Cylinder Removal and
Installation .........................................................5C-5
Clutch Operating Cylinder Assembly
Removal and Installation ...................................5C-5
Clutch Operating Cylinder Assembly
Inspection ..........................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Components ......................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation ...................................5C-7
Clutch Cover, Clutch Disc and Flywheel
Inspection ..........................................................5C-8
Specifications .......................................................5C-9
Tightening Torque Specifications ........................5C-9
Special Tools and Equipment ...........................5C-10
Recommended Service Material .......................5C-10
Special Tool ......................................................5C-10

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-1
Transmission / Transaxle
Automatic Transmission/Transaxle
Precautions
Precautions in Diagnosing TroubleS6RW0D5100001
• Do not disconnect couplers from TCM, battery cable
from battery, TCM ground wire harness from engine or
main fuse before checking the diagnostic information
(DTC, freeze frame data, etc.) stored in TCM memory.
Such disconnection will clear memorized information
in TCM memory.
• Diagnostic information stored in TCM memory can be
cleared as well as checked by using SUZUKI scan
tool or CAN communication OBD generic scan tool.
Before using scan tool, read its Operator’s
(Instruction) Manual carefully to have good
understanding as to what functions are available and
how to use it.
It is indistinguishable which module turns on MIL
because not only ECM but also TCM turns on MIL.
Therefore, check both ECM and TCM for DTC when
MIL lights on.
When checking TCM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– CAN communication OBD generic scan tool
displays DTC detected by each of ECM and TCM
simultaneously.
• Be sure to read “Precautions for Electrical Circuit
Service in Section 00” before inspection and observe
what is written there.
• TCM replacement
– When substituting a known-good TCM, check that
all relays and actuators have resistance of
specified value.
Neglecting this check may result in damage to good
TCM.
• Communication of ECM, BCM, combination meter,
keyless start control module (if equipped), ABS
control module, 4WD control module (if equipped),
TCM and DLC, is established by CAN (Controller
Area Network). (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Description”). Therefore,
handle CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
Precautions for Disassembly and ReassemblyS6RW0D5100002
When repairing automatic transaxle, it is necessary to
conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is
determined. If the transaxle is disassembled without
such preliminary procedure, not only the cause of the
trouble would be unknown, but also a secondary trouble
may occur and often time would be wasted.
As the automatic transaxle consists of high precision
component, the following cautions should be strictly
observed when handling its parts in disassembly and
reassembly.
• Disassembling valve body assembly is prohibited
essentially. However, a few parts can be
disassembled. When disassembling valve body
component parts, confirm whether their parts are
allowed to disassemble or not referring to “Valve Body
Assembly Disassembly and Reassembly”.
• When component part of forward clutch, direct clutch,
2nd brake and/or O/D and 2nd coast brake, namely
clutch disc, brake disc, retaining plate and/or
separator plate, 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”.
• Make sure to wash dirt off from the transaxle so that
no such dirt will enter the transaxle during
dismounting and remounting.
• Select a clean place free from dust and dirt for
overhauling.
• Place a rubber mat on the work bench to protect parts
from damage.
• Work gloves or shop cloth should not be used. (Use a
nylon cloth or a paper towel.)
• When separating the case joint, do not pry with a
screwdriver or such but tap with a plastic hammer
lightly.
• Make sure to wash dirt off from the transaxle so that
no such dirt will enter the transaxle during
disassembly and reassembly.
• Wash the disassembled parts in ATF (Automatic
Transaxle Fluid) or kerosene (using care not to allow
ATF or kerosene to get on your face, etc.) and confirm
that each fluid passage is not clogged by blowing air
into it. But use kerosene to wash the discs, resin
washers and rubber parts.
• Replace each gasket, oil seal and O-ring with a new
one.
• Apply ATF to sliding or rotating parts before
reassembly.

Downloaded from www.Manualslib.com manuals search engine 5A-2 Automatic Transmission/Transaxle:
CAUTION!
• Keep component parts in group for each
subassembly and avoid mixing them up.
• Clean all parts with cleaning solvent
thoroughly and air dry them.
• Use kerosene or automatic transaxle fluid
as cleaning solvent.
• Do not use wiping cloths or rags to clean
or dry parts.
• All oil passages should be blown out and
checked to make sure that they are not
obstructed.
• Keep face and eyes away from solvent
spray while air blowing parts.
• Check mating surface for irregularities and
remove them, if any, and clean it again.
• Soak new clutch discs and brake discs in
transaxle fluid for at least 2 hours before
assembly.
• Replace all gaskets and O-ring with new
ones.
• Apply automatic transaxle fluid to all O-
rings.
• When installing seal ring, be careful so that
it is not expanded excessively, extruded or
caught.
• Replace oil seals that are removed and
apply grease to their lips.
• Before installing, be sure to apply
automatic transaxle fluid to sliding, rolling
and thrusting surface of all component
part. Also after installation, make sure to
check each part for proper operation.
• Always use torque wrench when
tightening bolts.

• A new discs should be soaked in ATF at least 2 hours
before use.Part Inspection and Correction Table
Part Inspect for Correction
Casted part,
machined partSmall flaw, burr Remove with oil
stone.
Deep or grooved
flawReplace part.
Clogged fluid
passageClean with air or
wire.
Flaw on installing
surface, residual
gasketRemove with oil
stone or replace
part.
Crack Replace part.
Bearing Unsmooth rotation Replace.
Streak, pitting, flaw,
crackReplace.
Bushing, thrust
washerFlaw, burr, wear,
burningReplace.
Oil seal, gasket Flawed or
hardened seal ringReplace.
Worn seal ring on
its periphery or sideReplace.
Piston seal ring, oil
seal, gasket, etc.Replace.
Gear Flaw, burr Replace.
Worn gear tooth Replace.
Splined part Burr, flaw, torsion Correct with oil
stone or replace.
Snap ring Wear, flaw,
distortionReplace.
No interference Replace.
Thread Burr Replace.
Damage Replace.
Spring Settling, sign of
burningReplace.
Friction plate Wear, burning,
distortion,
damaged clawReplace.
Separator
plate, retaining
plateWear, burning,
distortion,
damaged clawReplace.
Sealing
surface (where
lip contacts)Flaw, rough
surface, stepped
wear, foreign
materialReplace.