2006 SUZUKI SX4 Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-129
2) Remove inner O-ring (1) and outer O-ring (2).Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new O-rings. Apply A/T fluid to the O-rings,
before installation.
• Install 2nd brake piston (1) to which A/T fluid is
applied to 2nd brake cylinder (2).
Do not damage O-ring when installing 2nd brake
piston.
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly ComponentsS6RW0D5106045
I2RH0B510198-01
I2RH0B510199-01
I5RW0C510063-01
1. Snap ring 5. O/D and 2nd coast brake piston 9. Rear cover plug O-ring
2. O/D and 2nd coast brake return spring subassembly 6. Rear cover seal ring : Apply automatic transaxle fluid.
3. O/D and 2nd coast brake piston front O-ring 7. Transaxle rear cover : Do not reuse.
4. O/D and 2nd coast brake piston rear O-ring 8. Rear cover plug : 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)

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 Automatic Transmission/Transaxle: 5A-131
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal rings and O-rings. Apply A/T fluid to
seal rings and O-rings before installation.
• Tighten rear cover plugs to specified torque.
Tightening torque
Rear cover plug: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
• Before installing rear cover seal ring, apply A/T fluid to
ring.
First, tighten seal ring to 5 mm (0.197 in.), then install
seal ring.
• Do not open rear cover seal ring too wide to attach.
• Do not damage O/D and 2nd coast brake return
spring subassembly and piston by pressing in O/D
and 2nd coast brake return spring subassembly
passing through its original installing position over 1.0
mm (0.039 in.).
Special tool
(A): 09926–96030
(B): 09946–06710Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Inspection
S6RW0D5106047
O/D and 2nd Coast Brake Return Spring
Subassembly
Measure free length of O/D and 2nd coast brake return
spring subassembly.
Free length of O/D and 2nd coast brake return spring
subassembly
“a”: 18.99 mm (0.748 in.)
NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.

Transaxle Rear Cover Bush
Measure transaxle rear cover bush bore by using special
tool.
If measured transaxle rear cover bush bore is out of
specifications, replace transaxle rear cover with new
one. In replacement, intermediate shaft subassembly
also needs to be checked. Replace intermediate shaft
subassembly, if necessary.
Special tool
(A): 09900–20605
Transaxle rear cover bush bore
Standard: 13.94 – 13.96 mm (0.549 – 0.550 in.)
1. Transaxle rear cover
1. Transaxle rear cover
I2RH0B510206-01
I2RH0B510201-01
I2RH0B510207-01
I2RH0B510208-01

Downloaded from www.Manualslib.com manuals search engine 5A-132 Automatic Transmission/Transaxle:
Countershaft Assembly ComponentsS6RW0D5106048
Countershaft Assembly Disassembly and
Reassembly
S6RW0D5106049
Disassembly
1) Remove countershaft LH bearing (1) and reduction
driven gear (2) at once by using special tool and
hydraulic press.
Special tool
(A): 09925–982212) Remove countershaft RH bearing (1) by using
special tools.
Special tool
(A): 09913–61510
(B): 09926–58010
Reassembly
1) Install new countershaft RH bearing (1) by using
special tool and hydraulic press.
Special tool
(A): 09913–84510
NOTE
Replace countershaft RH bearing together
with bearing cup as a set.

2) Install reduction driven gear (1) with special tools
and hydraulic press.
Special tool
(A): 09913–84510
(B): 09925–88210
1. Countershaft RH bearing 5. Bearing cap
2. Countershaft 6. Countershaft bearing shim
3. Countershaft LH bearing : Apply automatic transaxle fluid.
4. Reduction driven gear : Do not reuse.
I2RH0B510209-01
I2RH0B510210-01
I2RH0B510211-01
I2RH0B510212-01
I2RH0B510213-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-133
3) Install countershaft LH bearing (1) with special tools
and hydraulic press.
Special tool
(A): 09913–84510
(B): 09925–88210
Valve Body Assembly ComponentsS6RW0D5106050
I2RH0B510214-01
I4RS0A510044-01
1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid.
2. Shift solenoid valve-A (No.1) 7. Valve body assembly : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Shift solenoid valve-B (No.2) 8. Manual valve : Do not reuse.
4. TCC pressure control solenoid valve 9. Solenoid lock plate
5. Timing solenoid valve 10. O-ring

Downloaded from www.Manualslib.com manuals search engine 5A-134 Automatic Transmission/Transaxle:
Valve Body Assembly Disassembly and
Reassembly
S6RW0D5106051
CAUTION!
When replacing pressure control solenoid
valve and/or TCC pressure control solenoid
valve, it is strictly required to replace it
together with valve body assembly as a set.
Replacing pressure control solenoid valve
and/or TCC pressure control solenoid valve
independently may cause excessive shift
shock.

Disassembly
1) Pull out manual valve (1).
2) Remove pressure control solenoid valve (1).
3) Remove TCC pressure control solenoid valve (1).4) Remove shift solenoid valve-A (1).
5) Remove shift solenoid valve-B (1).
6) Remove timing solenoid valve (1).
7) Remove temperature sensor clamp (1).
2. Solenoid lock plate
I2RH0B510216-01
I2RH0B510217-01
1
I4RS0A510045-01
I2RH0B510219-01
I2RH0B510220-01
I2RH0B510221-01
I2RH0B510222-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-135
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Shift solenoid valve-A and -B are identical
• After applying A/T fluid to new O-rings, fit them to
solenoid valves, then install solenoid valves to valve
body.
• Tighten solenoid valve bolts to specified torque
Tightening torque
Solenoid valve bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Solenoid valve bolt specification
Differential Assembly ComponentsS6RW0D5106052
Bolt Length “a” Pieces
A (1) 49 mm (1.93 in.) 5
B (2) 20 mm (0.79 in.) 1
C (3) 60 mm (2.36 in.) 1
1
1 1
3
2
"a"
I4RS0A510046-01
I5RW0C510064-01
1. Differential side RH bearing 5. Side bearing shim : Apply automatic transaxle fluid.
2. Output shaft speed sensor (VSS) drive gear 6. Final gear bolt : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
3. Differential case subassembly 7. Side bearing cup : Do not reuse.
4. Final gear 8. Differential side LH bearing

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