brake SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-161
Specifications
Tightening Torque SpecificationsS6RW0D5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
A/T fluid drain plug 17 1.7 12.5) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor (VSS) bolt 13 1.3 9.5) / )
Input shaft speed sensor bolt 5.5 0.55 4.0) / )
Valve body harness connector bolt 5.5 0.55 4.0) / )
Shift solenoid bolt 11 1.1 8.0)
Oil strainer bolt 10 1.0 7.5) / )
Oil pan bolt 7.0 0.7 5.0) / )
Engine oil pan bolt 55 5.5 40.0)
Transaxle and engine fastening bolt 85 8.5 61.5)
Transaxle and engine fastening nut 85 8.5 61.5)
Drive plate to torque converter bolt 19 1.9 14.0)
Transaxle housing lower plate bolt 11 1.1 8.0)
Oil pump subassembly bolt 10 1.0 7.5)
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 11 1.1 8.0)
Final gear bolt 78 7.8 56.5)
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 33 3.3 24.0) / ) / )
Manual detent spring bolt 10 1.0 7.5)
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 25 2.5 18.0)
Fluid reservoir LH plate bolt 10 1.0 7.5)
Oil pump assembly bolt 25 2.5 18.0)
Transaxle case plug 7.5 0.75 5.5)
Valve body bolt 11 1.1 8.0)
Fluid cooler pipe union 25 2.5 18.0)
Fluid cooler pipe union bolt 35 3.5 25.5)
Fluid cooler pipe bracket bolt 10 1.0 7.5)
Fluid filler tube bolt 10 1.0 7.5)
Select cable bracket bolt 23 2.3 17.0)
Select cable clamp bolt 13 1.3 9.5)
Transmission range sensor lock nut 7 0.7 5.0)
Manual select lever nut 13 1.3 9.5)

Downloaded from www.Manualslib.com manuals search engine 5A-162 Automatic Transmission/Transaxle:
Special Tools and Equipment
Recommended Service MaterialS6RW0D5108001
NOTE
Required service material is also described in the following.
“Select Cable Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Direct Clutch Assembly Components”
“Forward and Reverse Clutch Assembly Components”
“2nd Brake Piston Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Countershaft Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Special ToolS6RW0D5108002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / )
SUZUKI Super Grease C P/No.: 99000–25030) / ) / ) / ) / ) / )
Sealant SUZUKI Bond No.1216B P/No.: 99000–31230) / ) / )
09900–20605 09900–20607
Dial calipers (1/100 mm, 10-
34 mm)Dial gauge
) / ) / )) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )
09900–20701 09913–50121
Magnetic stand Oil seal remover
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )) / )
09913–61510 09913–70123
Bearing puller Bearing installing tool
)) / )
09913–75510 09913–75810
Bearing installer Bearing installer
) / )) / )

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-163
09913–84510 09913–85210
Bearing installer Bearing installer
) / ) / ) / ))
09923–78210 09924–74510
Bearing installer Bearing and oil seal handle
)) / ) / ) / )
09925–37811–001 09925–88210
Oil pressure gauge Bearing puller attachment
)) / )
09925–98210 09925–98221
Input shaft bearing installer Bearing installer
))
09926–37610 09926–37610–001
Bearing remover Bearing puller
) / )) / )
09926–37610–002 09926–37610–003
Bearing puller attachment Bearing remover attachment
) / )) / )
09926–58010 09926–96030
Bearing remover attachment Clutch spring compressor
No.7
)) / )
09926–96050 09926–97610
Brake piston compressor Spring compressor
) / )) / )

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-1
Transmission / Transaxle
Manual Transmission/Transaxle
General Description
Manual Transaxle ConstructionS6RW0D5201001
The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three
shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a
sliding idler gear arrangement.
The low speed sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd gear, while
the high speed sleeve & hub is done on input shaft and engaged with input shaft 3rd gear or 4th gear. The 5th speed
sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on the input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used.
The device utilizes the 5th synchromesh, which is the lever synchro type, to apply the brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of
shifting to 2nd gear.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.
Further, care must be taken to adjust preload of countershaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.
2WD
I5RW0A520001-01
1. Input shaft 6. Input shaft 3rd gear 11. Countershaft 16. Countershaft 2nd gear

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 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

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-4
Clutch Fluid Pipe and Hose LocationS6RW0D5306004
Clutch Fluid Pipe Removal and InstallationS6RW0D5306005
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2).Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted
surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS6RW0D5306006
Check pipe (1) for damage, dirt and leak. Replace if
check result is not satisfactory.
4 [A]
3131
22
4
I5RW0A530003-02
[A]: RH steering vehicle 3. Clutch reservoir hose
1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
2
6
5 74
3
1
2
I5RW0B530002-03
[A]: LH steering vehicle
[B]: RH steering vehicle
I5RW0A530005-01

Downloaded from www.Manualslib.com manuals search engine 5C-5 Clutch:
Clutch Master Cylinder Removal and
Installation
S6RW0D5306007
Removal
1) Clean around brake master cylinder reservoir cap
and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe (4) from clutch master
cylinder (1) referring to “Clutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal, and then
remove clutch master cylinder.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch master cylinder nut to specified torque.
Tightening torque
Clutch master cylinder nut: 13 N·m (1.3 kgf-m, 9.5
lb-ft)
Clutch Operating Cylinder Assembly Removal
and Installation
S6RW0D5306008
CAUTION!
• Do not allow fluid to get on painted
surfaces. It may cause painted surface
damage.
• Do not disassemble clutch operating
cylinder assembly.

Removal
1) Clean around reservoir cap of brake master cylinder
and take out fluid with syringe or such.
2) Dismount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
3) Loosen clutch fluid pipe flare nut (1) of clutch
operating cylinder assembly (2).
4) Remove clutch pipe joint sleeve (3) from transaxle
and then remove clutch fluid pipe (4).
5) Remove clutch operating cylinder assembly from
transaxle.
3. Brake booster
1
3
2
4
I5RW0A530006-01
“A”
I5RW0A530007-01
3
4
2
1
I5RW0A530008-01

Downloaded from www.Manualslib.com manuals search engine Steering General Diagnosis: 6A-2
Steering System InspectionS6RW0D6104002
Check steering system referring to the following items.Erratic steering when
brakingWorn wheel bearingsReplace wheel bearing.
Broken or sagging coil springsReplace coil spring.
Wheel tires are inflated unequallyInflate tires to proper pressure.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Brakes not working in unisonCheck and repair brake system.
Leaking wheel cylinder or caliperRepair or replace wheel cylinder or caliper.
Warped discsReplace brake disc.
Badly worn brake liningsReplace brake shoe lining.
Drum is out of round in some brakesReplace brake drum.
Defective wheel cylindersReplace or repair wheel cylinder. Condition Possible cause Correction / Reference Item
Inspection Item Referring section
Steering wheel Play, rattle “Steering Wheel Play Check in Section 6C”
Tie-rod end Looseness and damage “Tie-Rod End Inspection in Section 6C”
Wheel alignment “Front Wheel Alignment Inspection and Adjustment in
Section 2B”
Tie-rod end boot Damage “Tie-Rod End Boot On-Vehicle Inspection in Section 6C”
Steering rack boot Damage “Steering Rack Boot Inspection in Section 6C”
Steering shaft joint Rattle and damage “Steering Shaft Joint On-Vehicle Inspection in Section 6C”
EPS system Operation “EPS System Check in Section 6C”

Downloaded from www.Manualslib.com manuals search engine 6C-38 Power Assisted Steering System:
2) Install steering gear case to vehicle, and then install
front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”.
3) Install steering gear case to suspension frame (3) as
follows.
a) Set member bracket (2) to steering gear case
(1).
b) Install all steering gear case mounting bolts by
hand.
c) Tighten steering mounting bolts in numerical
order and specified torque.
Tightening torque
Steering gear case mounting bolt (a): 70 N·m (
7.0 kgf-m, 51.0 lb-ft)
4) Connect torque sensor connector and P/S motor
connector to steering gear case.
5) Be sure that steering wheel and brake discs (right &
left) are all straight-ahead position and then insert
steering lower shaft (5) into steering pinion shaft (3)
with matching marks (4).
6) Tighten steering shaft joint lower bolt (1) and upper
bolt (2) to specified torque (tighten lower side first
and then tighten upper side).
Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
Steering lower shaft assembly lower joint bolt
(b): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
7) Install steering joint cover.Steering Rack Boot InspectionS6RW0D6306007
Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of
dust and water which can cause wear to steering rack
and pinion to produce noise as well as rust to result in
malfunction of steering system.
Even if boot tear is small, replace with new one.
Also, check each boot for dent. If there is a dent, keep
boot in most compressed state for some seconds to
correct dent.
Boots should be visually inspected for any damage, dent
and tear during every periodical inspection at specified
intervals and whenever vehicle is hoisted for any other
purpose.
Tie-Rod / Rack Boot Removal and InstallationS6RW0D6306008
Removal
1) Remove steering gear case assembly referring to
“Steering Gear Case Assembly Removal and
Installation”.
2) Remove member bracket from steering gear case
assembly.
3) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut position of tie-rod
thread.
4) Loosen tie-rod end lock nut and remove tie-rod end.
5) Remove boot band (2) and clip (1).
6) Remove boot from tie-rod.I7RW01632009-01
5
4 1, (b)
3
2, (a)
1, (b)5
I5RW0A630020-01
I2RH01630012-01
I4RS0A630044-01
IYSQ01630034-01