Oil SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
9) Install circlip (1) and confirm that circlip is installed in
groove securely.
Install needle bearing (2) and apply oil to needle
bearing.
With synchronizer outer ring (3), center cone (4) and
inner ring (5) put together and installed to 2nd gear
(6) as shown in figure.
10) Press-fit 3rd gear (2) and spacer (1) by using special
tools and hydraulic press.
NOTE
It is recommended to press-fit spacer and 3rd
gear first, and then 4th gear later separately
so that countershaft will not be compressed
excessively.

Special tool
(A): 09923–78210
(B): 09913–8521011) Press-fit 4th gear (2) by using the same procedure at
step 10).
12) Install left bearing cone (1) by using special tool and
hydraulic press.
NOTE
For protection of bearing cone (3), always
support shaft with special tool as shown in
figure.

Special tool
(A): 09923–78210
(E): 09913–80113
[A]: Section A – A
3. 2nd gear
I5RW0A520040-01
I4RH01520036-01
I2RH01520066-01

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

Downloaded from www.Manualslib.com manuals search engine 5B-36 Manual Transmission/Transaxle:
Differential ComponentsS6RW0D5206025
Differential Disassembly and ReassemblyS6RW0D5206026
Disassembly
1) Using special tool, remove left bearing (1).
Special tool
(A): 09913–65135
(B): 09913–852302) Using special tool, remove right bearing (1).
Special tool
(A): 09913–65135
(B): 09913–85230
(C): 09940–54950
I5RW0A520043-02
1. Differential pinion washer 6. Differential case : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
2. Differential pinion 7. Final gear : Do not reuse.
3. Differential side gear 8. Final gear bolt : Apply transaxle oil.
4. Side gear washer 9. Differential pinion shaft
5. Differential side bearing 10. Differential pinion shaft pin
(B)
(A)
1
I5RW0A520044-01
(A)
1
(B)
(C)
I5RW0A520045-01

Downloaded from www.Manualslib.com manuals search engine 5B-38 Manual Transmission/Transaxle:
4) Press-fit right bearing (1) by using special tools and
hydraulic press.
Special tool
(A): 09925–15410
(B): 09924–07720
(C): 09913–852305) Hold differential assembly with soft jawed vise (3),
install final gear (2) and then tighten new final gear
bolts (1).
CAUTION!
Use of any other bolts than specified ones is
prohibited. Otherwise, bolts may loosen.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS6RW0D5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Lever and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2. Differential case
3. Differential side left bearing
I5RW0A520048-01I5RW0A520049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transaxle oil level / filler plug 21 2.1 15.5) / )
Transaxle oil drain plug 21 2.1 15.5)
Back up light switch 23 2.3 17.0)
Guide case bolt No.1 23 2.3 17.0)
Guide case bolt No.2 23 2.3 17.0)
Gear shift interlock bolt 23 2.3 17.0)
5th to reverse interlock guide bolt 23 2.3 17.0)
Countershaft nut 100 10.0 75.0)
Shift fork shaft bolt 10 1.0 7.5)
Side cover bolt 10 1.0 7.5)
Reverse gear shift lever bolt 23 2.3 17.0)
Transaxle case bolt 23 2.3 17.0)
Reverse shaft bolt 23 2.3 17.0)
Gear shift locating bolt 13 1.3 9.5)
Left case plate bolt 23 2.3 17.0)
Oil gutter bolt 10 1.0 7.5)
Final gear bolt 90 9.0 65.0)

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-39
Special Tools and Equipment
Recommended Service MaterialS6RW0D5208001
NOTE
Required service material is also described in the following.
“Gear Shift Control Lever and Cable Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Input Shaft and Countershaft Components”
“Gear Shift Shaft Components”
“Differential Components”

Special ToolS6RW0D5208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / ) / ) / ) /
) / ) / )
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110) / ) / ) / ) / )
09900–06107 09900–20607
Snap ring pliers (opening
type)Dial gauge
) / ) / ) / ) / ) / ))
09900–20701 09913–50121
Magnetic stand Oil seal remover
))
09913–65135 09913–70123
Bearing puller Bearing installing tool
) / )) / )
09913–75510 09913–75810
Bearing installer Bearing installer
))
09913–75821 09913–75830
Bearing installer attachment Steering pinion bush
installer
))

Downloaded from www.Manualslib.com manuals search engine 5B-40 Manual Transmission/Transaxle:
09913–76010 09913–80113
Bearing installer Bearing installer
) / )) / ) / )
09913–84510 09913–85210
Bearing installer Bearing installer
)) / )
09913–85230 09922–85811
Bearing remover tool Spring pin remover (4.5 mm)
) / ) / )) / ) / )
09923–78210 09924–07710
Bearing installer Synchronizer hub installer
) / ) / ))
09924–07720 09924–74510
Synchronizer hub installer Bearing and oil seal handle
) / ))
09924–84510–004 09925–14520
Bearing installer attachment Bearing and oil seal installer
(80 x 50 mm)
))
09925–15410 09925–78210
Oil seal installer Spring pin remover (6 mm)
))
09927–76060 09930–30104
Gear holder Sliding shaft
) / ))

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-41
09940–54910 09940–54950
Front fork oil seal install
driverBearing installer attachment
))
09941–64511 09942–15511
Bearing and oil seal remover
(30 mm Min.)Sliding hammer
))
09944–96011 09952–06010
Bearing outer race remover Dial gauge plate No.1
))

Downloaded from www.Manualslib.com manuals search engine 5C-1 Clutch:
Transmission / Transaxle
Clutch
General Description
Clutch (Hydraulic Type) ConstructionS6RW0D5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.
I5RW0A530001-01
1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly
2. Flywheel 5. Clutch cover 8. Input shaft bearing
3. Clutch disc 6. Diaphragm spring 9. Input shaft

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-2
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS6RW0D5304001
Condition Possible cause Correction / Reference Item
SlippingImproper clutch pedal free travelBleed air or replace master cylinder.
Worn or oily clutch disc facingReplace disc.
Warped disc, pressure plate or flywheel
surfaceReplace disc, clutch cover or flywheel.
Weakened diaphragm springReplace clutch cover.
Master cylinder piston or seal cup not
returningReplace master cylinder.
Dragging clutchImproper clutch pedal free travelBleed air or replace master cylinder.
Weakened diaphragm spring, or worn
spring tipReplace clutch cover.
Rusted input shaft splinesLubricate.
Damaged or worn splines of transaxle
input shaftReplace input shaft.
Excessively wobbly clutch discReplace disc.
Clutch facings broken or dirty with oilReplace disc.
Fluid leakageRepair or replace.
Clutch vibrationGlazed (glass-like) clutch facingsRepair or replace disc.
Clutch facings dirty with oilReplace disc.
Release bearing slides unsmoothlyReplace clutch operating cylinder assembly.
Wobbly clutch disc, or poor facing
contactReplace disc.
Weakened torsion springs in clutch discReplace disc.
Clutch disc rivets looseReplace disc.
Distorted pressure plate or flywheel
surfaceReplace clutch cover or flywheel.
Weakened engine mountingReplace engine mounting.
Loosened engine mounting bolt or nutRetighten engine mounting bolt or nut.
Noisy clutchWorn or broken release bearingReplace clutch operating cylinder assembly.
Input shaft front bearing worn downReplace input shaft bearing.
Excessive rattle of clutch disc hubReplace disc.
Cracked clutch discReplace disc.
Pressure plate and diaphragm spring
rattlingReplace clutch cover.
Grabbing clutchClutch disc facings soaked with oilReplace disc.
Clutch disc facings excessively wornReplace disc.
Rivet heads showing out of facingReplace disc.
Weakened torsion springsReplace disc.

Downloaded from www.Manualslib.com manuals search engine 5C-3 Clutch:
Repair Instructions
Clutch Pedal InspectionS6RW0D5306001
Cylinder Push Rod Play “a”
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).
Clutch Pedal Free Travel “b”
1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel
“b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.
Clutch Release Margin “c”
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
Clutch release margin
“c”: 25 – 55 mm (0.98 – 2.17 in.)6) If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”.Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS6RW0D5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to the reservoir cap of the brake master
cylinder.
Air Bleeding of Clutch SystemS6RW0D5306003
CAUTION!
When operating the pedal stroke for air
bleeding of clutch system, after releasing the
clutch pedal, be sure to wait 1 second or
more before depressing it again. Otherwise,
the oil seal of operating cylinder will be
damaged, resulting in oil leakage.

Bleed air from clutch system.
Refer to “Air Bleeding of Brake System in Section 4A”.
I5RW0A530002-01