2006 SUZUKI SX4 Gear shift

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-15
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly
S6RW0D5206013
1) Push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12
in.) commercially available spring pin remover and
specified spring pin removers as shown bellow.
Special tool
(A): 09922–85811 4.5 mm
(B): 09925–78210 6.0 mm
2) Inspect component parts for wear, distortion or
damage. If any detect is found, replace detective
part with new one.
NOTE
• When driving in spring pins, prevent shaft
from being bent by supporting it with wood
block.
• Assemble 5th & reverse gear shift cam
with its pit and spring pin aligned.
• Make sure to select an appropriate spring
by identifying the painted colors to keep
gear shifting performance as designed.
– Low speed select spring - Light blue
– Reverse select spring - Pink

1. E-ring 8. Spring pin
2. Washer 9. Gear shift & select shaft
3. Reverse select spring 10. 5th & reverse gear shift cam
4. Gear shift interlock plate 11. Cam guide return spring
5. Ball 12. 5th & reverse gear shift cam guide
6. Gear shift interlock spring 13. Low speed select spring
7. Gear shift & select lever 14. Spring pin remover
I6RW0C520002-01

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
Manual Transaxle Assembly ComponentsS6RW0D5206014
I5RW0A520018-03
1. Transaxle right case 22. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case
: Apply sealant 99000-31260 to mating surface of left case and right
case.23. 5th gear shift fork
3. Gear shift and select shaft assembly
: Apply sealant 99000-31260 to mating surface of guide case and left
case.24. Needle bearing
4. Transaxle left case plate 25. Input shaft 5th gear
5. Transaxle side cover
: Apply sealant 99000-31260 to mating surface of side cover and left
case.26. Reverse gear shift lever
6. Back up light switch 27. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring28. Reverse gear shaft
8. Differential assembly 29. Washer
9. Oil level / filler plug
: Apply sealant 99000-31260 to all around thread part of plug.30. Reverse idler gear

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 Manual Transmission/Transaxle: 5B-19
7) Fit 5th gear shift fork (1) to sleeve (3) and hub (2)
assembly, and install them into input shaft and gear
shift shaft, aligning punch mark (4) with matching
mark (5) on input shaft.
8) Tighten shift fork shaft bolt (2) to which thread lock
cement has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Shift fork shaft bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-
ft)
9) Using special tool, install new circlip (1) to input shaft
(3).
Special tool
: 09900–0610710) Clean mating surface of both left case and side
cover (1), apply sealant to side cover as shown in
figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate it with left case, and
then tighten side cover bolts with specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Manual Transaxle Assembly Disassembly and
Reassembly
S6RW0D5206016
Disassembly
1) Remove left case plate bolts (1), and take off left
case plate (2).
I3RH0A520080-01
2, (a), “A”
13
I5RW0A520019-013. Input shaft
I5RW0A520020-01
I4RH01520018-01

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-21
Reassembly
1) Install differential assembly into right case.
2) Join input shaft (5), countershaft (4), low speed gear
shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, then install them into right
case (1) so as not to damage oil seal by input shaft
spline.
NOTE
• Input shaft right bearing on shaft can be
installed into right case (1) by tapping shaft
with plastic hammer.
• Make sure that countershaft is engaged
with final gear while installing.

3) Install 5th & reverse gear shift shaft (1) with 5th &
reverse gear shift guide shaft (2) into right case (5).
Reverse gear shift arm (4) has to be joined with
reverse gear shift lever (3) at the same time.4) Make reverse idler gear (1) with reverse gear shift
lever (2), insert reverse gear shaft (3) and washer (6)
into case (4) through idler gear and then align bolt
hole “a” in shaft with notch “b” in case.
5) Fasten reverse gear shift lever bolts (5) after
applying thread lock cement.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
NOTE
Check to confirm that reverse gear shift lever
end has clearance “c” to idler gear groove.

Distance between lever end and idler gear shaft
“c”: 0.5 – 1.0 mm (0.02 – 0.04 in.)
I2RH01520080-01
I3RH0A520013-01
I5RW0A520022-02

Downloaded from www.Manualslib.com manuals search engine 5B-22 Manual Transmission/Transaxle:
6) Clean mating surfaces of both right and left cases,
apply sealant to left case (2) as shown in the figure
by such amount that its section is 1.5 mm (0.059 in.)
in diameter then mate it with right case (1).
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
7) Tighten case bolts (3) from outside and tighten
another case bolts from clutch housing side to
specified torque.
Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
8) Install reverse shaft bolt (4) to which thread lock
cement has been applied, with aluminum washer
and tighten it to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Reverse shaft bolt (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft)9) Check locating springs (2, 4 and 5) for deterioration
and replace with new ones as necessary.
Locating spring
10) Install steel balls (3) and locating springs (2, 4 and 5)
for respective gear shift shaft and tighten bolts (1) to
which thread lock cement has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Gear shift locating bolt (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
11) Install new snap ring (1) using special tool.
Special tool
(A): 09900–06107
I5RW0A520023-01
Locating spring free length Standard Service limit
Low speed (2)53.1 mm
(2.091 in.)47.8 mm
(1.881 in.)
High speed (4)45.9 mm
(1.807 in.)41.4 mm
(1.629 in.)
5th & reverse (5)29.9 mm
(1.777 in.)27.0 mm
(1.062 in.)
2. Input shaft
3. Input shaft left bearing
1, (a), “A”
2
3
4
5
I5RW0A520024-02
1 (A)
2
3
I3RH0A520016-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-35
Gear Shift Shaft ComponentsS6RW0D5206022
5th and Reverse Gear Shift Shafts Disassembly
and Reassembly
S6RW0D5206023
Disassembly
Disassemble component parts by using special tool and
hammer.
Special tool
: 09922–85811
Reassembly
Replace or correct parts as required and assemble
shafts making sure that component parts are in proper
order as shown in figure.
NOTE
Install 2 steel balls (3) in reverse gear shift
arm (1) without fail.

Gear Shift Shaft and Fork InspectionS6RW0D5206024
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds limit of 1.0 mm (0.039 in.).
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Service limit: 1.0 mm (0.039 in.)
2) Insert each gear shift shaft into case and check that
it moves smoothly. If it doesn’t, correct by using
oilstone, reamer or the like.
I5RW0A520041-01
1. Low speed gear shift shaft 4. 5th & reverse gear shift guide shaft 7. 5th & reverse gear shift yoke
2. High speed gear shift shaft 5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
3. 5th & reverse gear shift shaft 6. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
2. Spring 6. 5th & reverse gear shift yoke
4. Spring pin 7. 5th & reverse gear shift guide shaft
5. 5th & reverse gear shift shaft
I5RW0A520042-01
I2RH01520068-01