lock SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5A-154 Automatic Transmission/Transaxle:
57) Apply A/T fluid to direct clutch assembly (1).
Install direct clutch assembly while rotating
clockwise and counterclockwise frequently to fit
clutch discs to mating hub.
NOTE
Before installation, align teeth of direct clutch
discs to facilitate installation.

58) Check for correct installation of direct clutch
assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
direct clutch assembly, direct clutch hub and reinstall
them properly.
Distance between direct clutch assembly and
mating surface of transaxle case
“a”: 10.5 – 11.3 mm (0.413 – 0.445 in.)59) Install oil pump assembly (1) to transaxle case.
Tightening torque
Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
60) Make sure that input shaft (1) turns smoothly.
I2RH0B510309-01
“a”
“a”
1
2
I2RH0B510310-01
I2RH0B510311-01
I2RH0B510312-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-159
83) Install select cable bracket (1).
Tightening torque
Select cable bracket bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
84) Apply A/T fluid to O-rings of each sensor and install
input shaft speed sensor (1) and output shaft speed
sensor (VSS) (2).
Tightening torque
Input shaft speed sensor bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
Output shaft speed sensor (VSS) bolt (b): 13
N·m (1.3 kgf-m, 9.5 lb-ft)
85) Install harness bracket and select cable clamp (3).
Tightening torque
Select cable clamp bolt (c): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
86) Install transmission range sensor to transaxle case,
tighten bolts temporarily at this step.87) Install lock washer (1) and tighten lock nut (2) to
specified torque.
Tightening torque
Transmission range sensor lock nut (a): 7 N·m (
0.7 kgf-m, 5.0 lb-ft)
88) Install manual select lever (1) temporarily at this
step.
89) After shifting manual select lever counterclockwise
fully, select “N” range position by bringing it back 2
notches clockwise.
90) Remove manual select lever (1) at this step.
91) Loosen sensor bolts (4) and align needle direction
shaped on lock washer (2) with “N” reference line (3)
on transmission range sensor by moving sensor in
rotative direction.
92) Tighten sensor bolts to specified torque.
Tightening torque
Transmission range sensor bolt (b): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
93) Bend dents of lock washer (1) in order to prevent
displacement of lock washer.
1
(a)I5RW0C510069-02
(a)13
(c)
2(b)
I2RH0B510330-01
1I2RH0B510331-01
1
2, (a)
I2RH0B510332-01
132
4, (b)
4, (b)
I2RH0B510333-01
I2RH0B510334-01

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 Manual Transmission/Transaxle: 5B-3
Gear Shift Mechanism
The gear shifting control system consists of the following main parts. Movement of gear shift control lever is
transmitted to gear shift & select shaft through gear shift and gear select cables.
I5RW0A520003-02
1. Gear shift control cable 7. Reverse gear shift lever 13. Gear shift & select lever
2. Gear select control cable 8. 5th & reverse gear shift guide shaft 14. Low speed gear shift shaft
3. Select cable lever 9. 5th & reverse gear shift shaft 15. High speed gear shift shaft
4. Shift cable lever 10. Gear shift & select shaft assembly 16. Gear shift control lever assembly
5. 5th & reverse gear shift cam 11. 5th to reverse interlock guide bolt
6. 5th gear shift fork 12. Gear shift interlock bolt

Downloaded from www.Manualslib.com manuals search engine 5B-4 Manual Transmission/Transaxle:
5th & Reverse Gear Shift Cam
5th & reverse gear shift cam, cam guide return spring
and 5th to reverse interlock guide bolt are provided to
prevent the gear from being directly shifted from 5th to
reverse.
1) When shift lever is at neutral position between 3rd
and 4th gear, shift cam (2) is under guide bolt and
can turn freely clockwise (to 3rd gear) and
counterclockwise (to 4th gear).
2) When shift lever is shifted toward the right from
neutral position, shift and select shaft (1) moves up
but shift cam (2) is restricted by guide bolt and return
spring is contracted.3) When shift lever is shifted to 5th gear, shift & select
shaft (1) turns clockwise letting shift cam (2) off from
guide bolt and pushed up by return spring. In this
state, movement of shift cam is restricted by guide
bolt and therefore, gearshift to reverse is not
attainable.
4) When shift lever is shifted from neutral position
between 5th gear and reverse gear to reverse gear,
shift cam (2) turns counterclockwise to attain reverse
gear.
1. Shift & select shaft
3. Return spring (expanded)
4. Reverse select spring (expanded)
3. Reverse select spring (contracted)
I2RH01520003-02
I2RH01520004-01
I2RH01520005-01
3. Reverse select spring (expanded)
1. Shift & select shaft
3. Return spring (contracted)
4. Reverse select spring (contracted)
I2RH01520006-01
I2RH01520007-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Gear Shift Control Lever and Cable Removal
and Installation
S6RW0D5206005
Removal
1) Remove console box.
2) Disconnect cable ends (5) from pivot (6) of gear shift
control lever assembly by removing clip.
3) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly (2) while
pulling quick joint (4) as shown in figure.
4) Remove gear shift control lever assembly mounting
nuts (3) and gear shift lever assembly from floor
panel.
5) Disconnect gear shift and select control cables from
transaxle.
6) Remove cable grommet bolt, and then remove gear
shift and select control cables from floor panel.
Installation
Reverse removal procedure for installation nothing the
following.
• Tighten each bolts and nuts to specified torque
referring to “Gear Shift Control Lever and Cable
Components”.
• Adjust gear select control cable referring to “Gear
Select Control Cable Adjustment”.
Gear Select Control Cable AdjustmentS6RW0D5206006
1) Release lock plate (1) which restricts moving of
cable end holder (2).
2) Push cable end holder (2) out from adjuster (4) using
appropriate tool (3) to disengage cable.
36
5
2
3
41
I4RS0A520003-01
I4RS0A520004-01

Downloaded from www.Manualslib.com manuals search engine 5B-10 Manual Transmission/Transaxle:
3) Apply grease to pin (5) of gear shift control lever, and
then install adjuster (1) into pin of gear shift control
lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in the direction of A.
NOTE
At this time, do not apply force in the cable
operation direction B to adjuster.

5) Slide lock plate (3) in the direction of C, until it gets
over the claw (4) of cable end holder.
Back Up Light Switch Removal and InstallationS6RW0D5206007
Removal
1) Remove battery and tray with ECM.
2) Disconnect back up light switch coupler (1).
3) Remove back up light switch.
Installation
1) Apply oil to new O-ring (1) and tighten back up light
switch (2) to specified torque.
Tightening torque
Back up light switch (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
2) Connect back up light switch coupler.
3) Install battery and tray with ECM.
Back Up Light Switch InspectionS6RW0D5206008
Check back up light switch for function using ohmmeter.
Switch ON (Push): Continuity
Switch OFF (Release): No continuity
3
3
41
2
A C
1
B
5, “A”
I4RS0A520005-01
2. Gear shift and select shaft assembly
2
1I5RW0A520009-01
1 2, (a)
I3RH0A520006-01
I5RW0A520050-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-13
Gear Shift and Select Shaft Assembly ComponentsS6RW0D5206011
1
10
3
4
9
2
6
12
7
11
5
8(a)
(a)
(a)
(a)1217G
1217G
1217G
A13
I6RW0C520001-01
1. Gear shift & select shaft 7. Gear shift guide case bolt No.1
: Apply sealant 99000-31260 to bolt thread.13. Oil seal
: Apply grease 99000-25011 to oil seal lip.
2. 5th & reverse gear shift cam 8. Gear shift guide case bolt No.2 : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Gear shift interlock plate 9. 5th to reverse interlock guide bolt
: Apply sealant 99000-31260 to bolt thread.: Do not reuse.
4. Gear shift & select lever 10. Gear shift interlock bolt
: Apply sealant 99000-31260 to bolt thread.: Apply transaxle oil.
5. Shift cable lever 11. Guide case
6. Select cable lever 12. Select lever bush

Downloaded from www.Manualslib.com manuals search engine 5B-14 Manual Transmission/Transaxle:
Gear Shift and Select Shaft Assembly Removal
and Installation
S6RW0D5206012
Removal
1) Remove battery and tray with ECM.
2) Disconnect gear shift and gear select control cables
from transaxle.
3) Remove gear shift interlock bolt (1) and 5th to
reverse interlock guide bolt (2) from transaxle case.
4) Remove gear shift & select shaft assembly (3).
Installation
1) Clean mating surface of guide case (1) and left case
(5), apply sealant to left case as shown in figure by
such amount that its section is 1.5 mm (0.059 in.) in
diameter, mate guide case with left case.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
2) Install guide case bolts No.1 to which sealant has
been applied and guide case bolts No.2 (2), and
tighten them to specified torque.
: Sealant 99000–31260 (SUZUKI Bond No.1217G)
Tightening torque
Guide case bolt No.1: 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
Guide case bolt No.2 (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)3) Install washer and gear shift interlock bolt (3) to
which sealant has been applied and then tighten it to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift interlock bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
4) Install washer and 5th to reverse interlock guide bolt
(4) to which sealant has been applied and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
5th to reverse interlock guide bolt (c): 23 N·m (
2.3 kgf-m, 17.0 lb-ft)
5) Connect gear shift and gear select control cables to
transaxle.
6) Install battery and tray with ECM.
7) Check input shaft for rotation in each gear position.
4. Transaxle side cover
3
1
2
4
I5RW0A520016-01
I5RW0A520017-02

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-15
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly
S6RW0D5206013
1) Push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12
in.) commercially available spring pin remover and
specified spring pin removers as shown bellow.
Special tool
(A): 09922–85811 4.5 mm
(B): 09925–78210 6.0 mm
2) Inspect component parts for wear, distortion or
damage. If any detect is found, replace detective
part with new one.
NOTE
• When driving in spring pins, prevent shaft
from being bent by supporting it with wood
block.
• Assemble 5th & reverse gear shift cam
with its pit and spring pin aligned.
• Make sure to select an appropriate spring
by identifying the painted colors to keep
gear shifting performance as designed.
– Low speed select spring - Light blue
– Reverse select spring - Pink

1. E-ring 8. Spring pin
2. Washer 9. Gear shift & select shaft
3. Reverse select spring 10. 5th & reverse gear shift cam
4. Gear shift interlock plate 11. Cam guide return spring
5. Ball 12. 5th & reverse gear shift cam guide
6. Gear shift interlock spring 13. Low speed select spring
7. Gear shift & select lever 14. Spring pin remover
I6RW0C520002-01