2006 SUZUKI SX4 manual transaxle oil

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-121
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal ring and O-ring. Apply A/T fluid before
installation.
• Do not damage direct clutch return spring
subassembly (1) and piston by pressing in direct
clutch return spring subassembly passing through its
original installing position over 0.7 mm (0.027 in.).
Special tool
(A): 09926–98310
• Apply A/T fluid to direct clutch separator plates (4),
discs (3) and retaining plate (2).
• Install direct clutch separator plates (4), discs (3),
retaining plate (2) and snap ring (1) to input shaft
subassembly.
• Install plate snap ring so that its both ends would be
positioned in correct locations as shown in figure.• After assembly, measure direct clutch piston stroke.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
When piston stroke is out of specification, select direct
clutch retaining plate with suitable thickness from
among the following table and replace it.
Available direct clutch retaining plate thickness
I2RH0B510168-01
I2RH0B510169-01
[A]: Correct [B]: Incorrect
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
2.8 mm (0.110 in.) 4
1. Direct clutch assembly 3. Oil hole
2. Oil pump assembly
I2RH0B510170-01
I2RH0B510171-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-123
Forward and Reverse Clutch Assembly ComponentsS6RW0D5106039
Forward and Reverse Clutch Assembly
Preliminary Check
S6RW0D5106040
1) Install forward and reverse clutch assembly (1) to
transaxle rear cover (2), blow in compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) through oil
hole (4) of transaxle rear cover with the special tool
attached on the upper surface of reverse clutch
retaining plate (3), and measure reverse clutch
piston stroke.
If piston stroke exceeds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
I3RM0B510061-01
1. Forward clutch balancer 8. Intermediate shaft seal ring 15. Forward clutch retaining plate
2. Forward clutch return spring subassembly 9. Reverse clutch plate snap ring 16. Forward clutch disc
3. Forward clutch piston 10. Reverse clutch retaining plate 17. Forward clutch separator plate
4. Forward clutch piston O-ring 11. Reverse clutch separator plate 18. Balancer snap ring
5. Forward clutch drum 12. Reverse clutch disc : Apply automatic transaxle fluid.
6. Forward clutch drum O-ring 13. Reverse clutch cushion plate : Do not reuse.
7. Intermediate shaft subassembly 14. Forward clutch plate snap ring
I2RH0B510176-01

Downloaded from www.Manualslib.com manuals search engine 5A-124 Automatic Transmission/Transaxle:
2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm2,
57 – 113 psi) through oil hole (1) of transaxle rear
cover with the special tool attached on the upper
surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
If piston stroke exceeds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Forward and Reverse Clutch Assembly
Disassembly and Reassembly
S6RW0D5106041
CAUTION!
When clutch disc, retaining plate and/or
separator plate of forward clutch 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.

Disassembly
1) Remove reverse clutch plate snap ring (1) and take
out reverse clutch retaining plate, discs, separator
plates and clutch cushion plate from intermediate
shaft subassembly.2) Remove forward clutch plate snap ring (1) and take
out forward clutch retaining plate, discs and
separator plates from forward clutch drum.
3) Remove balancer snap ring by using special tool and
hydraulic press.
Special tool
(A): 09926–97610
CAUTION!
Do not press forward clutch return spring
subassembly in over 1.5 mm (0.059 in.).
Excessive compression may cause damage
to return spring subassembly and/or
balancer.

4) Remove forward clutch balancer (1).
5) Remove forward clutch return spring subassembly
(1).
I2RH0B510177-02
I2RH0B510178-01
2. Intermediate shaft subassembly
I2RH0B510179-01
I2RH0B510180-01
I2RH0B510181-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-125
6) Install intermediate shaft subassembly (1) to
transaxle rear cover (2). Apply compressed air (400
– 800 kPa, 4 – 8 kg/cm
2, 57 – 113 psi) to oil hole (3)
of transaxle rear cover to remove forward clutch
piston (4).
7) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of transaxle rear cover to
remove forward clutch drum (2).
8) Remove forward clutch piston O-ring (1) from
intermediate shaft subassembly (2).9) Remove forward clutch drum O-ring (1) from forward
clutch drum (2).
10) Remove intermediate shaft seal ring (1) from
intermediate shaft subassembly (2).
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Before assembling, apply automatic transaxle fluid to
component parts.
• Replace O-rings and seal ring with new ones.
• Do not damage forward clutch return spring
subassembly and balancer (1) by pressing forward
clutch return spring subassembly passing through its
original installing position over 1.5 mm (0.059 in.).
Special tool
(A): 09926–97610
I2RH0B510182-01
I2RH0B510183-01
I2RH0B510184-01
I2RH0B510185-01
I2RH0B510186-01
I2RH0B510180-01

Downloaded from www.Manualslib.com manuals search engine 5A-126 Automatic Transmission/Transaxle:
• Apply A/T fluid to forward clutch separator plates (1),
discs (2) and retaining plate (3).
• Install forward clutch separator plates (1), discs (2)
and retaining plate (3), then snap ring (4) to forward
clutch drum.
• Install forward clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.• Measure forward clutch piston stroke in the same
manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
forward clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Available forward clutch retaining plate thickness
• Install reverse clutch cushion plate (1) in correct
direction as shown in figure.
• Apply A/T fluid to reverse clutch cushion plate (1),
reverse clutch separator plate (2), discs (3) and
retaining plate (4).
• Install reverse clutch cushion plate (1), reverse clutch
separator plate (2), discs (3), retaining plate (4) and
then snap ring (5) to intermediate shaft subassembly.
[A]: Correct [B]: Incorrect
4
1 2 3
I5RW0C510062-01
I2RH0B510188-01
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.1 mm (0.122 in.) 5
3.2 mm (0.126 in.) 2
3.3 mm (0.130 in.) 6
3.4 mm (0.134 in.) 3
3.5 mm (0.138 in.) 7
3.6 mm (0.142 in.) 4
1. Oil hole
I2RH0B510177-02
I3RM0B510062-01

Downloaded from www.Manualslib.com manuals search engine 5A-128 Automatic Transmission/Transaxle:
Forward Clutch Piston Lip and Forward Clutch
Balancer Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.Forward Clutch Drum Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
2nd Brake Piston Assembly ComponentsS6RW0D5106043
2nd Brake Piston Assembly Disassembly and
Reassembly
S6RW0D5106044
Disassembly
1) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of 2nd brake cylinder (3)
to remove 2nd brake piston (2).
I2RH0B510194-01
I2RH0B510195-01
I2RH0B510196-01
1. 2nd brake cylinder 4. Outer O-ring
2. 2nd brake piston : Apply automatic transaxle fluid.
3. Inner O-ring : Do not reuse.
I2RH0B510197-01

Downloaded from www.Manualslib.com manuals search engine 5A-130 Automatic Transmission/Transaxle:
Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Disassembly and
Reassembly
S6RW0D5106046
Disassembly
1) Remove snap ring by using special tools and
hydraulic press.
Special tool
(A): 09926–96030
(B): 09946–06710
CAUTION!
Do not press O/D and 2nd coast brake return
spring subassembly in over 1.0 mm (0.039
in.).
Excessive compression may cause damage
to O/D and 2nd coast brake return spring
subassembly and/or piston.

2) Remove O/D and 2nd coast brake return spring
assembly.
3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (2) of transaxle rear cover (1)
to remove O/D and 2nd coast brake piston.4) Remove O/D and 2nd coast brake piston front O-ring
(1) and rear O-ring (2).
5) Remove rear cover seal rings (1).
6) Remove rear cover plugs (1).
1. Transaxle rear cover
I2RH0B510201-01
I2RH0B510202-01
I2RH0B510203-01
I2RH0B510204-01
I2RH0B510205-01

Downloaded from www.Manualslib.com manuals search engine 5A-136 Automatic Transmission/Transaxle:
Differential Assembly Disassembly and
Reassembly
S6RW0D5106053
Disassembly
1) Remove final gear bolts (1), and then final gear (2).
2) Remove differential side RH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
3) Remove output shaft speed sensor (VSS) drive gear
(1).4) Remove differential side LH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
Reassembly
WARNING!
• When taking warmed final driven gear out
of vessel, use tongs or the like. Taking out
it with bare hand will cause severe burn.
• While installing warmed final driven gear,
use oven glove such as leather glove.
Picking up it with bare hand may cause
burn.

CAUTION!
Do not leave final driven gear in boiling water
for longer than 5 min. Overheating the gear
may cause strength reduction of gear.

1) Put final driven gear in water vessel, heat and
remove when it boils, then remove moisture.
NOTE
After removing moisture on final driven gear,
install final driven gear to differential case as
quickly as possible.

2. Differential case subassembly
I2RH0B510225-01
I2RH0B510226-01
I2RH0B510227-01
I2RH0B510228-01
I2RH0B510229-01