2006 SUZUKI SX4 rear assembly

Downloaded from www.Manualslib.com manuals search engine 5A-4 Automatic Transmission/Transaxle:
I5RW0C510070-01
1. Drive plate 11. 1st and reverse brake 21. Rear sun gear
2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear
3. Torque converter 13. Long planet pinion 23. Short planet pinion
4. Input shaft 14. One-way No.2 clutch 24. Countershaft
5. Oil pump 15. 2nd brake 25. Reduction driven gear
6. Direct clutch drum (double as sensor rotor for input shaft
speed sensor)16. One-way No.1 clutch 26. Differential case assembly
7. Direct clutch 17. O/D and 2nd coast brake 27. Final gear
8. Parking lock gear 18. Intermediate shaft 28. Output shaft speed sensor (VSS) drive gear
9. Reduction drive gear 19. Forward clutch
10. Planet carrier 20. Reverse clutch

Downloaded from www.Manualslib.com manuals search engine 5A-30 Automatic Transmission/Transaxle:
Manual Road TestS6RW0D5104011
WARNING!
Carry out test in very little traffic area to prevent an accident.
Test requires 2 persons, a driver and a tester.

The purpose of this test is to judge whether causal factor of trouble which occurred in automatic transaxle is electrical
or mechanical by disconnecting valve body harness connector (1) and fixing automatic transaxle gear position.
1) Start engine and warm it up to normal operating temperature.
2) Turn ignition switch to OFF position and disconnect valve body harness connector (1).
3) Turn OFF all electrical loads.
With select lever shifted to each range (“L”, “2”, “3” and “D”), drive vehicle at 1,000 rpm engine speed and then
check vehicle speed by referring to “Fixed gear position”.
If vehicle speed is not as specified in “Fixed gear position” table, go to troubleshooting.
4) Connect valve body harness connector and clear DTC.
Fixed gear position
Troubleshooting
Engine Brake TestS6RW0D5104012
WARNING!
Before test, make sure that there is no vehicle behind so as to prevent rear-end collision.

1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake
operates.
2) In the same way as in Step 1), check engine brake for operation when select lever is shifted down to “L” range.
3) Engine brake should operate in the test.
TroubleshootingSelect lever position Fixed gear position Vehicle speed
L range
3rd gear Approx. 25.0 km/h (15.5 mile/h) 2 range
3 range
D range
R range Reverse gear Approx. 10.9 km/h (6.8 mile/h)
1
I5RW0C510010-01
Condition Possible cause Correction / Reference Item
Operated gear is not
correctFaulty valve body componentReplace valve body assembly.
Faulty clutch or brakeInspect clutch and brake. If any parts are faulty,
replace them.
Condition Possible cause Correction / Reference Item
Failure to operate when
shifted down to “2” rangeFaulty valve body componentReplace valve body assembly.
Faulty O/D and 2nd coast brakeInspect. If NG, replace.
Failure to operate when
shifted down to “L” rangeFaulty valve body componentReplace valve body assembly.
Faulty 1st and reverse brakeInspect. If NG, replace.

Downloaded from www.Manualslib.com manuals search engine 5A-32 Automatic Transmission/Transaxle:
Time Lag TestS6RW0D5104014
This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range and measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from “N” to “R” range.
Gear shifting time lag
“N” → “D”: Less than 0.7 sec.
“N” → “R”: Less than 1.2 sec.
NOTE
• When repeating this test, be sure to wait at least one minute after select lever is shifted back to “N”
range.
• Engine should be warmed up fully for this test.
• Repeat test 3 times and take average of those data for final time lag data.

Troubleshooting
Line Pressure TestS6RW0D5104015
Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line.
Line pressure test requires the following conditions.
• Automatic fluid is at normal operating temperature (70 – 80 °C / 158 – 176 °F).
• Fluid is replenished to proper level (between FULL and LOW on dipstick).
• Air conditioner switch is turned OFF.
1) Apply parking brake securely and place chocks against wheels.
2) Remove fluid pressure check hole plug bolt.
3) Attach oil pressure gauge to fluid pressure check hole in transaxle case.
Special tool
(A): 09925–37811–001Condition Possible cause Correction / Reference Item
“N”
→ “D” time lag
exceeds specificationMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
“N”
→ “R” time lag
exceeds specificationMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-108 Automatic Transmission/Transaxle:
29) Remove input shaft rear thrust bearing (1) and thrust
bearing race (2).
NOTE
If input shaft rear thrust bearing is not found,
it may have been taken out with direct clutch
assembly.

30) Remove direct clutch hub (1).
31) Remove differential assembly (1) and countershaft
assembly (2).32) Remove governor apply No.2 gasket (1).
33) Remove fluid reservoir LH plate (1).
34) Turn over transaxle and remove rear cover assembly
(1).
35) Remove reverse clutch drum thrust bearing (1).
NOTE
If reverse clutch drum thrust bearing is not
found, it may have been taken out with rear
cover assembly.

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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-109
36) Remove 2nd brake gasket (1).
37) Measure O/D and 2nd coast brake piston stroke.
If piston stroke exceeds specification, inspect and
replace plates and discs.
• Measure dimension “a” from mating surface of
transaxle case to O/D and 2nd coast brake rear
plate (1) using straightedge and micrometer
caliper.
• Measure dimension “b” from O/D and 2nd coast
brake piston (2) to rear cover assembly mating
surface using straightedge and micrometer
caliper.
• Calculate piston stroke from measured value of
dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.)
CAUTION!
When brake disc, retaining plate, separator
plate and/or rear plate of O/D and 2nd coast
brake 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.

38) Remove forward and reverse clutch assembly (1).
39) Remove intermediate shaft thrust bearing front race
(1), thrust bearing (2) and rear race (3) from forward
and reverse clutch assembly (4).
NOTE
If intermediate shaft thrust bearing and/or
races are not found on forward and reverse
clutch assembly, they may have been left in
transaxle.

I2RH0B510109-01
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Downloaded from www.Manualslib.com manuals search engine 5A-110 Automatic Transmission/Transaxle:
40) Remove O/D and 2nd coast brake rear plate (1),
discs (2), separator plate (3) and retaining plate (4).
41) Remove forward clutch hub (1).
42) Remove rear sun gear thrust bearing (1) from
forward clutch hub (2).
NOTE
If rear sun gear thrust bearing is not found on
forward clutch hub, it may have been left in
transaxle.

43) Remove rear sun gear thrust bearing race (1).44) Remove rear planetary sun gear subassembly (1)
and one-way clutch No.1 assembly (2).
45) Remove planetary gear thrust bearing (1).
NOTE
If planetary gear thrust bearing is not found
on one-way clutch No.1 assembly, it may
have been left in transaxle.

46) Remove one-way clutch No.1 assembly (2) from rear
planetary sun gear subassembly (3).
47) Remove planetary carrier thrust washer (1).
I2RH0B510113-01
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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