shaft 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-155
61) Measure input shaft thrust play.
Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
When input shaft thrust play is out of specification,
select input shaft front thrust bearing with proper
thickness from among the following table and
replace it.
Available input shaft front thrust bearing
thickness
62) After applying A/T fluid to new O-ring, fit it to
breather union (2). Then install breather union to
transaxle case.
63) Install breather hose (1).
64) Wipe off and clean mating surface between
transaxle case (1) and torque converter housing.
65) Apply sealant to torque converter housing by using a
nozzle (2) as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)66) Install torque converter housing to transaxle case,
tighten bolts to specified torque.
CAUTION!
Apply sealant to threads of four bolts shown
in figure before tightening.

“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Tightening torque
Torque converter housing bolt (a): 33 N·m (3.3
kgf-m, 24.0 lb-ft)
67) After applying A/T fluid to new O-ring, fit it to
transaxle case plug (1). Then install the transaxle
case plug to transaxle case (2).
Tightening torque
Transaxle case plug (a): 7.5 N·m (0.75 kgf-m, 5.5
lb-ft) ThicknessOutside
diameterInside diameter
3.45 mm
(0.14 in.)48.5 mm
(1.90 in.)32.9 mm
(1.30 in.)
4.05 mm
(0.16 in.)48.5 mm
(1.90 in.)32.5 mm
(1.28 in.)
I2RH0B510313-01
I2RH0B510314-01
12
“A”
I2RH0B510315-01
I3RM0B510069-01
I2RH0B510317-01

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 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 5B-2 Manual Transmission/Transaxle:
4WD
2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub
3. Input shaft 5th gear 8. Reverse gear shaft 13. Countershaft 5th gear 18. Countershaft 1st gear
4. Input shaft 4th gear 9. Reverse idler gear 14. Countershaft 4th gear 19. Final gear
5. High speed sleeve & hub 10. Right case 15. Countershaft 3rd gear 20. Differential case
I5RW0A520002-05
1. Input shaft 8. Reverse gear shaft 15. Countershaft 3rd gear 22. Transfer driven gear
2. 5th speed sleeve & hub 9. Reverse idler gear 16. Countershaft 2nd gear 23. Transfer bevel gear
3. Input shaft 5th gear 10. Right case 17. Low speed sleeve & hub 24. Transfer bevel pinion
4. Input shaft 4th gear 11. Countershaft 18. Countershaft 1st gear 25. Transfer right case
5. High speed sleeve & hub 12. Side cover 19. Final gear 26. Transfer left case
6. Input shaft 3rd gear 13. Countershaft 5th gear 20. Differential case 27. Transfer output flange
7. Left case 14. Countershaft 4th gear 21. Transfer intermediate shaft 28. Transfer output retainer

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