2006 SUZUKI SX4 Sas

Downloaded from www.Manualslib.com manuals search engine 3C-5 Transfer:
Transfer Assembly Disassembly and
Reassembly
S6RW0D3306005
Disassembly
NOTE
It is possible to disassemble transfer
assembly without removing intermediate
shaft with Step 1) to 4) performed if not
necessary.

1) Remove right case oil seal No.1 (1) from transfer
right case using special tool.
Special tool
: 09913–50121
2) Remove snap ring (2) by using snap ring pliers.
3) Remove intermediate shaft (4) with intermediate
shaft bearing (3) from transfer assembly.
4) Remove intermediate shaft bearing (3) from
intermediate shaft (4) by using bearing puller and
hydraulic press.
5) Remove transfer output retainer assembly (1) and
shim (3) by removing retainer bolts (2).
6) Remove transfer case bolts (4).
7) Separate transfer right case (5) from transfer left
case (6) by using special tool.
Special tool
(A): 09912–34510
8) Remove reduction drive gear assembly (7) and
reduction driven gear assembly (9).
9) Remove shim (10) and bearing outer races (8).
NOTE
When it is difficult to remove bearing outer
races from cases, remove them with special
tool.

Special tool
(B): 09944–96011Reassembly
1) Select appropriate shim as follows.
a) Measure distance “a” between taper roller
bearing outer races of reduction driven gear
assembly (1).
b) Measure depth “b” of left case (2) and “c” of right
case (3).
c) Obtain adjusting shim thickness by the following
equation.
9. Pump seal 23. Reduction drive gear right bearing : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
10. Pinion shaft front taper roller bearing 24. Intermediate shaft : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
11. Bevel pinion 25. Oil protect plate bolt
: Apply thread lock cement 99000-32110
to thread part.: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
12. Bevel gear 26. Snap ring : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
13. Reduction driven gear 27. Oil protect plate : Do not reuse.
14. Intermediate shaft bearing 28. Shim : Apply transfer oil.
4
3
2
1
I5RW0A330008-01
11. Dowel pin
Necessary
shim
thickness=Depth
“b”+Depth
“c”–Distanc
e “a”+0.1 mm
(0.004
in.)
7
(B)
5
11
310 9 10
8 64
8
(A)
12
2
I5RW0A330009-03
23
1
“b”
“a”“c”
I5RW0A330010-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-6
d) Select a shim which is close to half thickness of
the calculated value (necessary shim thickness)
from among the available shims to install it
between bearing and case at each of right and
left sides.
For example:
Measure distance “a” is 110.75 mm (4.360 in.).
Measure depth “b” is 85.8 mm (3.378 in.).
Measure depth “c” is 26.55 mm (1.045 in.).
Necessary shim thickness = 85.8 mm (3.378 in.)
+ 26.55 mm (1.045 in.) – 110.75 mm (4.360 in.) +
0.1 mm (0.004 in.) = 1.7 mm (0.067 in.)
1.7 mm (0.067 in.) ÷ 2 = 0.85 mm (0.033 in.)
Calculated thickness of new shim = 0.85 mm
(0.033 in.)
Available reduction driven gear shim
thickness
0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95,
1.00 and 1.05 mm (0.024, 0.026, 0.028, 0.030,
0.031, 0.033, 0.035, 0.037, 0.039 and 0.041 in.)
2) Clean mating surface of right and left cases, and
apply sealant to right case (1) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
3) Assemble the following parts in right and left cases
by reversing disassembling procedure.
• Reduction drive gear assembly (1)
• Reduction driven gear assembly (3)
• Bearing outer races (2)
• Reduction driven gear shims (5)
• Dowel pin (6)
4) Tighten transfer case bolts (4) to specified torque.
Tightening torque
Transfer case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)5) Select bevel pinion shim (3) referring to step 1) of
“Reassembly” under “Transfer Output Retainer
Assembly Disassembly and Reassembly”.
6) Inspect tooth contact according to “Bevel Gear Tooth
Contact Inspection”.
7) Install transfer output retainer assembly (2) with
bevel pinion shim (3) to transfer left case (4) by
tightening retainer bolt (1) to specified torque.
Tightening torque
Transfer output retainer bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)
8) Install bolt to bolt hole of flange (2), set dial gauge
measuring tip at right angles to bolt (1) as shown in
figure. Holding reduction driven gear by hand, take
measurement backlash of pinion and bevel gear.
NOTE
If backlash exceeds specification given
below, adjust it by changing thickness ratio
of shims assembled in right and left cases in
Step 3).

Special tool
(A): 09900–20607
(B): 09900–20701
Bevel pinion & bevel gear backlash
: 0.1 – 0.2 mm (0.0039 – 0.0078 in.)
1
“A”
I5RW0A330011-01
6
4, (a) 5 2
31
2
5
I5RW0A330012-02
4
3
21, (a)
1, (a)
I5RW0A330013-02
(A)
1
(B)
2
I5RW0A330014-02

Downloaded from www.Manualslib.com manuals search engine 3C-7 Transfer:
9) Install intermediate shaft bearing (1) to intermediate
shaft (2) by using special tool.
Special tool
(A): 09913–84510
10) Install intermediate shaft (2) with bearing (3) in
transfer.
11) Install new snap ring (1) to transfer right case by
using snap ring pliers.
12) Apply grease to new right case oil seal No.1 lip.
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
13) Drive right case oil seal No.1 (1) in transfer right
case (2) by using special tool and hammer.
Special tool
(A): 09925–15410
Intermediate output oil seal installing depth
“a”: 1.0 – 1.5 mm (0.04 – 0.06 in.)
Reduction Drive Gear Assembly Disassembly
and Reassembly
S6RW0D3306006
Disassembly
Remove bearings (1) from reduction drive gear (2) using
special tool, bearing puller (3) and hydraulic press (4).
Special tool
(A): 09913–85230
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one as
necessary.
2) Install bearings (1) to reduction drive gear (2) using
special tool, bearing puller (3) and hydraulic press
(4).
Special tool
(A): 09913–85230
(A)
1
2
I5RW0A330015-01
132
I5RW0A330016-02
(A)
1, “A”
2
2
“a”
I5RW0A330017-02
4
(A)2
1
3I5RW0A330018-01
(A)
2
4
1
3I5RW0A330019-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-8
Reduction Driven Gear Assembly Disassembly
and Reassembly
S6RW0D3306007
Disassembly
1) Remove left bearing (1) and bevel gear (2) using
special tool, bearing puller (3) and hydraulic press
(4).
Special tool
(A): 09925–98221
2) In order to remove right bearing (1) from reduction
driven gear (2), grind with a grinder (3) one part “a”
of bearing as illustrated till it becomes thin.
CAUTION!
Be careful not to grind too far not to damage
reduction driven gear.

3) Break with a chisel (1) the thin ground bearing (2),
and it can be removed.Reassembly
CAUTION!
• Bevel gear and pinion must be replaced as
a set when either replacement becomes
necessary.
• When replacing taper roller bearing,
replace as inner race and outer race
assembly.

1) Install right bearing (1) to reduction driven gear (2)
using special tools and hydraulic press.
Special tool
(A): 09924–74510
(B): 09925–16310
2) Install bevel gear (1) to reduction driven gear (2)
using special tools and hydraulic press.
Special tool
(A): 09924–07710
(B): 09924–84510–005
(C): 09925–154104
(A)1
23
I5RW0A330020-02
1
2
3
1
2“a”
I5RW0A330021-01
1
2I5RW0A330022-01
(A)
(B)
1
2
I5RW0A330023-01
(C)
(A)
2
1
(B)
I5RW0A330024-01

Downloaded from www.Manualslib.com manuals search engine 3C-9 Transfer:
3) Install left bearing (1) to reduction driven gear (2)
using special tools and hydraulic press.
Special tool
(A): 09913–84510
(B): 09924–84510–005
Transfer Right Case and Left Case Disassembly
and Reassembly
S6RW0D3306008
Disassembly
1) Remove oil seals from right case (1) using special
tool, if necessary.
Special tool
(A): 09925–15410
2) Remove oil plate (1) from right case (2), if necessary.
3) Remove oil seals from left case using flat end rod or
the like, if necessary.Reassembly
1) When installing oil seal No.2 (1) and No.3 (2) to right
case (3) using special tool, use care so that oil seals
in proper direction and position as shown in figure.
Apply grease to oil seal lip.
Special tool
(A): 09925–15410
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Oil seals installing depth
“a”: 23.5 – 24.0 mm (0.925 – 0.945 in.)
“b”: 38.0 – 39.0 mm (1.496 – 1.535 in.)
2) Install oil plate to right case.
Tightening torque
Oil plate bolt: 9 N·m (0.9 kgf-m, 6.5 lb-ft)
3) When installing new oil seal No.1 (1) and No.2 (2) to
left case (3) using special tool, use care so that oil
seals in proper direction as shown in figure.
Apply grease to oil seal lip.
Special tool
(A): 09913–85210 (For oil seal No.1)
(A): 09944–88210 (For oil seal No.2)
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
(A)
1
2
(B)I5RW0A330025-02
(A)
1
I5RW0A330026-01
1
2
I5RW0A330027-01
1, “A”
2, “A”“a”
(A)
3 “b”
I5RW0A330028-01
3
(A)
2, “A”1, “A”I5RW0A330029-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-10
Transfer Output Retainer Assembly
Disassembly and Reassembly
S6RW0D3306009
Disassembly
1) Uncaulk transfer output flange nut.
2) Remove transfer output flange nut while holding
flange (1) by using special tool.
Special tool
(A): 09930–40113
3) Remove transfer output flange (1) by bearing puller
(2).
4) Drive out bevel pinion (1) from transfer output
retainer by tapping it with plastic hammer (2).5) Drive out front taper roller bearing (1) from bevel
pinion (3) by using bearing puller (2) and hydraulic
press.
6) Remove oil seal (1) by using special tool.
Special tool
(A): 09913–50121
7) Remove rear taper roller bearing (1), pump seal (3)
and spacers (2).
8) Drive out outer races (2) (front and rear) by using
brass bar (1).
(A)
1
I5RW0A330030-01
2
1
I5RW0A330031-01
1 2
I3RH01332019-01
3
12
I5RW0A330032-01
1(A)
I3RH01332020-01
1
2
3
I5RW0A330033-03
11
2
2I5RW0A330034-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-14
8) Install transfer output flange (1) by tapping with
plastic hammer and tighten transfer output flange nut
gradually so as rotational torque of bevel pinion to be
in specified value.
NOTE
• If rotational torque of bevel pinion exceeds
specification given in the following,
replace pinion shaft spacers and tighten
flange nut.
• Before taking measurement of rotational
torque, rotate pinion over ten rounds in
advance.

Bevel pinion bearing preload
: 0.5 – 1.3 N⋅m (0.05 – 0.13 kgf-m, 0.35 – 0.95 lb-ft)
Special tool
(A): 09930–40113
9) Caulk transfer output flange nut (1).
Transfer Assembly InspectionS6RW0D3306010
• Check each bearing for smooth rotation, wear or
discoloration
If found abnormal, replace.
• Check oil seal for leakage and its lip for excessive
hardness
If either is found, replace.
• Check transfer case for cracks.
• Check bevel pinion and bevel gears for wear or
cracks.
Bevel Gear Tooth Contact InspectionS6RW0D3306011
1) After cleaning tooth surface of bevel gear (1), paint
them with gear marking compound evenly by using
brush or sponge etc.
NOTE
When applying red lead paste to teeth, be
sure to paint tooth surfaces uniformly. The
paste must not be too dry or too fluid.

2) Install transfer output retainer assembly referring to
“Transfer Assembly Disassembly and Reassembly”.
3) Turn transfer output flange clockwise and
counterclockwise repeatedly, and remove transfer
output retainer assembly and bevel gear shims from
transfer assembly.
2. Torque wrench
(A)1
2
I5RW0A330043-01
1
I5RW0A330044-01
I3RH01332043-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1
Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1
Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System
Construction (If Equipped) ................................ 4A-2
Front Brake Hose / Pipe Construction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4
Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7
Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-7
Brake Fluid Level Inspection ............................... 4A-8
Brake Light Switch Adjustment ........................... 4A-8
Air Bleeding of Brake System ............................. 4A-8
Front Brake Hose / Pipe Removal and
Installation ......................................................... 4A-9
Rear Brake Hose / Pipe Removal and
Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-10
Master Cylinder and Brake Booster
Components.................................................... 4A-11
Master Cylinder Reservoir Removal and
Installation ....................................................... 4A-11
Master Cylinder Removal and Installation......... 4A-12
Master Cylinder Inspection ............................... 4A-13
Booster Operation Inspection ........................... 4A-14
Brake Booster Removal and Installation ........... 4A-15
Brake Booster Inspection .................................. 4A-15
Booster Push Clevis Rod Adjustment ............... 4A-16
Specifications..................................................... 4A-16
Tightening Torque Specifications ...................... 4A-16
Special Tools and Equipment ........................... 4A-16
Recommended Service Material ....................... 4A-16
Special Tool ...................................................... 4A-16
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and
Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Caliper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and
Assembly........................................................... 4B-4
Front Disc Brake Caliper Inspection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .......................................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipment .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Drum Brake Components ...........................4C-1
Rear Brake Drum Removal and Installation ........4C-2
Rear Brake Drum and Shoe Inspection ..............4C-2
Rear Brake Shoe On-Vehicle Inspection ............4C-3
Rear Brake Shoe Removal and Installation ........4C-3
Rear Brake Shoe Inspection ...............................4C-4
Wheel Cylinder Removal and Installation ...........4C-4
Wheel Cylinder Inspection ..................................4C-5
Brake Back Plate Removal and Installation ........4C-5
Specifications .......................................................4C-6
Tightening Torque Specifications ........................4C-6
Special Tools and Equipment .............................4C-6
Recommended Service Material .........................4C-6
Parking Brake .......................................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1
Repair Instructions ..............................................4D-2
Parking Brake Inspection and Adjustment ..........4D-2
Parking Brake Cable Removal and
Installation .........................................................4D-2
Parking Brake Lever Removal and Installation ....4D-3