2006 SUZUKI SX4 engine

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-105
9) Remove fluid cooler pipes (1) and pipe unions (2).
10) Remove fluid level gauge (3) and fluid filler tube (4).
11) Remove oil pan (1) and oil pan gasket (2).
NOTE
• For removal of oil pan, do not turn
transaxle over as this will contaminate
valve body with foreign materials in
bottom of oil pan.
• When removing oil pan, tap around it
lightly with plastic hammer. Do not force it
off by using screwdriver or the like.

12) Remove oil strainer assembly (1).13) Disconnect connectors (2) from solenoid valves and
transmission fluid temperature sensor (1).
14) Remove valve body assembly bolts.
CAUTION!
Be careful not to let manual valve fall off
when removing valve body assembly.

NOTE
There are five kinds of bolts (bolts A (1), B (2),
C (3), D (4) and E (5)) fixing valve body
assembly.

15) Remove manual valve rod (1) from manual valve
lever (2), then remove valve body assembly (3).
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Downloaded from www.Manualslib.com manuals search engine 5A-106 Automatic Transmission/Transaxle:
16) Remove valve body harness (1).
CAUTION!
When pulling valve body harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

17) Remove governor apply No.1 gasket (1).
18) Remove cooler check valve (1) and spring (2).19) Remove accumulator pistons and springs.
To remove C2 (1), C1 (2) and B1 (3) accumulator
pistons and springs, position rag on pistons to catch
each piston. To remove pistons, force low-pressure
compressed air (1 kg/cm
2, 15 psi, 100 kPa, max) into
hole (4) as shown in figure, and pop each piston into
rag.
NOTE
Do not push accumulator pistons with
fingers or anything before removing them.
Pushing them may cause compressed fluid
in accumulator to spew out of hole and get to
your face and clothes.

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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-107
20) Remove transaxle case plug (1).
21) Remove torque converter housing bolts.
22) Remove torque converter housing (1) while tapping
around it lightly with plastic hammer.
23) Remove breather hose (1).
24) Remove breather union (2).
25) Measure input shaft thrust play.
Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
When input shaft thrust play is out of specification,
select input shaft front thrust bearing with proper
thickness from among the list below and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
Available input shaft front thrust bearing
thickness
“a”: 0.8, 1.4 mm (0.032, 0.055 in.)26) Remove oil pump assembly (1).
27) Remove direct clutch assembly (1).
28) Remove input shaft front thrust bearing (1).
NOTE
If input shaft front thrust bearing is not
found, it may have been taken out with oil
pump assembly.

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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.

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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).
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-111
48) Remove O/D and 2nd coast brake retaining plate
snap ring (1).
49) Remove front planetary sun gear (1).
50) Remove front sun gear thrust bearing race (2) from
front planetary sun gear (1).
51) Before disassembling 2nd brake piston assembly
(4), check 2nd brake piston stroke by measuring
clearance between 2nd brake separator plate (1)
and piston (2) with feeler gauge (3).
If clearance, that is, piston stroke is out of
specification, replace brake discs and plates with
new ones.
CAUTION!
When brake disc, retaining plate and/or
separator plate of 2nd 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.

2nd brake piston stroke
“a”: 0.40 – 1.25 mm (0.016 – 0.049 in.)
52) Using special tool and hydraulic press, remove 2nd
brake piston snap ring (1).
CAUTION!
Do not press 2nd brake piston assembly in
over 0.4 mm (0.016 in.).
Excessive compression may cause damage
to piston assembly, return spring, plates and/
or discs.

Special tool
(A): 09926–96050
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Downloaded from www.Manualslib.com manuals search engine 5A-112 Automatic Transmission/Transaxle:
53) Remove 2nd brake piston assembly (1).
54) Remove 2nd brake return spring subassembly (2).
55) Remove 2nd brake separator plates (1), discs (2)
and retaining plate (3).
56) Remove brake drum gasket (1).
57) Remove one-way clutch outer race retainer (1).58) Check one-way clutch No.2 as follows.
• Ensure planetary carrier (1) rotates only in
counterclockwise direction “A”, never in clockwise
direction “B”.
• If the planetary carrier rotates both ways or does
not rotate either way, one-way clutch No.2
assembly will need to be replaced with new one-
way clutch No.2 assembly.
59) Remove one-way clutch No.2 assembly (1).
60) Remove planetary gear assembly (1).
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