transaxle SUZUKI SX4 2006 1.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-7
1) Set parking brake and place automatic transaxle in
PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line,
add distilled water.
3) Attach end of one jumper cable to positive terminal
of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to
negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn
off electrical accessories. Then start engine of the
vehicle with discharged battery.
6) Disconnect jumper cables in the exact reverse order.
With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS6RW0D1A06002
Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (4).
4) Remove battery (1).
Handling
When handling battery, the following safety precautions
should be followed:
• Hydrogen gas is produced by battery. A flame or
spark near battery may cause the gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing
or other fabric. Any spilled electrolyte should be
flushed with large quantity of water and cleaned
immediately.Remounting
1) Reverse removal procedure.
2) Tighten battery cables securely.
NOTE
Check to be sure that ground cable has
enough clearance to hood panel by terminal.

Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1A06006
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
cap is taken off too soon.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 10kg or 22 lb.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 4.0 – 4.5mm (0.16 – 0.18 in.) as
deflection / 10 kg (22 lbs)
1. Battery 4. Retainer
2. Positive cable 5. Nut
3. Negative cable
21
4
3
5I7RW011A0005-01

Downloaded from www.Manualslib.com manuals search engine 3A-1 Drive Shaft / Axle: Front
Driveline / Axle
Drive Shaft / Axle
Front
General Description
Front Drive Shaft ConstructionS6RW0D3111001
A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For A/T
vehicle, a tripod type constant velocity joint is used on the differential side and center shaft side. For M/T vehicle, a
double offset type constant velocity joint (DOJ) is used on the differential side and center shaft side. The drive shaft
can slide through the tripod joint or the double offset joint (DOJ) in the extension/contraction direction.
Component Location
Front Drive Shaft Assembly Components LocationS6RW0D3113001
I6RW0D311001-01
1. To transaxle 7. Wheel nut : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)
2. Drive shaft assembly 8. Center shaft assembly (if equipped) : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
3. Tie-rod end 9. Center bearing support bolts (if equipped) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
4. Tie-rod end nut 10. Washer : Do not reuse.
5. Ball stud bolt : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. Drive shaft nut
: After tightening nut to specified torque,
caulk nut securely.:60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 3A-3 Drive Shaft / Axle: Front
Front Drive Shaft Assembly On-Vehicle
Inspection
S6RW0D3116002
• Check boots for breakage or deterioration.
• Check wheel side joint for rattle or smooth rotation.
• Check differential side (or center shaft side) joint for
smooth rotation.
If any abnormality is found, replace.
Front Drive Shaft Assembly Removal and
Installation
S6RW0D3116003
Removal
1) Hoist vehicle and remove front wheel.
2) Undo caulking and remove drive shaft nut (1) with
brake pedal depressed.
3) Drain transaxle oil and transfer oil (4WD model).
4) Disconnect tie-rod end (1) from steering knuckle (2)
using puller (3).5) Remove brake hose mounting bolt (1) and brake
hose (2) from bracket and then detach wheel speed
sensor harness (3) from strut bracket.
6) Remove suspension control arm ball joint bolt (4)
from knuckle.
7) Disconnect front suspension control arm ball joint
stud from steering knuckle.
8) Using tire lever (1) or plastic hammer (3), pull out
drive shaft joint (2) so as to release snap ring fitting
of joint spline at differential side, at center shaft or at
transfer side.
I6RW0B310005-01
I3RM0A310003-01
[A]: Left side shaft
[B]: Right side shaft of 2WD vehicle
[C]: Right side shaft of 4WD vehicle
I6RW0D311003-01
I5RW0A311003-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-4
9) Remove drive shaft assembly.
10) Remove center bearing support bolts (3) and remove
center bearing support (2) with center shaft (1) from
differential side gear, if equipped.
Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.
• Make sure that differential side joint is
inserted fully and its snap ring is seated as
it was.

Install drive shaft assembly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque
referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as specified referring to “Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A” and “Transfer Oil Change in
Section 3C” (4WD model).
• Check toe setting referring to “Front Wheel Alignment
Inspection and Adjustment in Section 2B” and adjust
as required.
Front Drive Shaft Disassembly and ReassemblyS6RW0D3116004
Disassembly
For DOJ type
CAUTION!
Disassembly of wheel side joint is not
allowed. If any noise or damage exists in it,
replace it as assembly.

1) Remove differential side (or center shaft side) boot
big band (1) as follows.
• For boot big band without joint [A]:
Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint [B]:
Draw hooks of boot big band together and remove
band.3
2
1I2RH01310007-01
I4RH0A310004-01

Downloaded from www.Manualslib.com manuals search engine 3B-11 Differential:
Visual InspectionS6RW0D3204004
Check the following parts and systems visually.
DTC CheckS6RW0D3204005
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to SUZUKI scan tool operator’s manual for further
details.
If communication between SUZUKI scan tool and
4WD control module is not possible, check if
SUZUKI scan tool is communicable by connecting it
to 4WD control module in another vehicle. If
communication is possible in this case, SUZUKI
scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle
with which communication was not possible.
5) After completing the check, turn ignition switch OFF
and disconnect SUZUKI scan tool from data link
connector (DLC).
DTC ClearanceS6RW0D3204006
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Erase DTC according to instructions displayed on
SUZUKI scan tool. Refer to SUZUKI scan tool
operator’s manual for further details.
5) After completing clearance, turn ignition switch OFF
and disconnect SUZUKI scan tool from data link
connector (DLC).
6) Perform “DTC Check” and confirm that NO CODES
is displayed.
NOTE
DTC stored in 4WD control module memory
are also cleared in the following cases. Be
careful not to clear them before keeping their
record.
• When power to 4WD control module is cut
off (by disconnecting battery cable,
removing fuse or disconnecting 4WD
control module connectors).
• When the same malfunction (DTC) is not
detected again during 40 engine warm-up
cycles.

Inspection Item Referring
• Rear differential oil ---- level, leakage “Rear Differential Oil Change”
• Transfer gear oil ---- level, leakage “Transfer Oil Change in Section 3C”
• Manual transmission oil ---- level, leakage “Manual Transaxle Oil Change in Section 5B”
• Rear differential mounting(s) ---- wear and looseness
• Fuses ---- burning
• Battery ---- fluid level, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ---- disconnection,
friction“Intermittent and Poor Connection Inspection in Section
00”
• Other parts that can be checked visually
1(A)I5RW0A320008-011(A)I5RW0A320008-01

Downloaded from www.Manualslib.com manuals search engine 3C-1 Transfer:
Driveline / Axle
Transfer
General Description
Transfer DescriptionS6RW0D3301001
The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in
transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction
drive gear, reduction driven gear and bevel gear of transfer. As bevel gears, which change the direction of driving
torque axis to the direction of the angle with 90 degrees, hypoid gears are provided. Hypoid gears have an advantage
of preventing gear noise, at the same time, they require accurate adjustment of tooth contact and backlash.
Diagnostic Information and Procedures
Transfer Symptom DiagnosisS6RW0D3304001
2
1
8
34
5
6
7
9
10I5RW0A330001-01
1. Intermediate shaft 5. Reduction driven gear 9. Transfer output retainer
2. Left case 6. Bevel gear 10. Transfer output flange
3. Reduction drive gear 7. Bevel pinion
4. Right case 8. Spacer
Condition Possible cause Correction / Reference Item
NoiseInadequate or insufficient lubricantReplenish.
Damaged or worn bearing(s)Replace.
Damaged or worn gear(s)Replace.
Preload of taper roller bearing is
reducedAdjust.

Downloaded from www.Manualslib.com manuals search engine 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-4
• Pour transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change in Section 5B” and “Transfer Oil
Change”.
Transfer Assembly ComponentsS6RW0D3306004
1
2
6
9
1110
8
7
3A
4
5
36
OIL
(a) 5
(a)
OIL
28
18
30
27
25
21
28
13
12
22OIL
OIL
32A
31A
1322(d)
34A
33
23A
2019
(c)1217G
291217G
(b)
35
15A
26
26 14
24
17
161217G(b)
A
I5RW0A330007-05
1. Transfer output flange nut
: After tightening nut so as rotational torque
of bevel pinion to be in specified value,
caulk nut securely.15. Dowel pin 29. Transfer right case
: Apply sealant 99000-31260 to
mating surface with right case.
2. Transfer output flange 16. Oil drain plug
: Apply sealant 99000-31260 to thread
part.30. Oil level / filler plug
: Apply sealant 99000-31260 to
thread part.
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.17. Transfer left case
: Apply grease 99000-25010 to left case.31. Left case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
4. Pinion shaft rear taper roller bearing 18. Transfer case bolt 32. Left case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
5. Transfer output retainer bolt 19. Reduction drive gear left bearing 33. Right case oil seal No.3
: Apply grease 99000-25010 to oil
seal lip.
6. O-ring
: Apply grease 99000-25010 to all around
surface.20. Reduction drive gear 34. Right case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
7. Shim 21. Reduction driven gear left taper roller
bearing35. Right case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
8. Spacer 22. Reduction driven gear right taper roller
bearing36. Transfer output retainer

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-16
Specifications
Tightening Torque SpecificationsS6RW0D3307001
NOTE
The specified tightening torque is also described in the following.
“Transfer Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. These contact patterns, located on toe or heel on both
drive and coast sides, mean that 1) both pinion and gear
are defective, 2) retainer is not true, or 3) gear is not
properly seated on transfer case. The remedy is to
replace the defective member.
Irregular patterns: If the pattern is not oval, it means that
bevel gear is defective. High or low spots on tooth
surfaces or on the seat of bevel gear are the cause of
irregular patterns appearing on some teeth. The remedy
is to replace the pinion and gear set and, if the seat is
defective, so is transfer case. Tooth contact pattern Diagnosis and remedy
I3RH01332048-01
I3RH01332049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transfer oil level / filler plug 23 2.3 17.0) / )
Transfer oil drain plug 23 2.3 17.0)
Stiffener No.1 bolt and No.2 bolt 55 5.5 40.0)
Transfer to transaxle bolt 98 9.8 71.0)
Transfer case bolt 23 2.3 17.0)
Transfer output retainer bolt 55 5.5 40.0)
Oil plate bolt 9 0.9 6.5)
Rotational torque of bevel pinion (Bearing
preload)0.50 – 1.30 0.05 – 0.13 0.35 – 0.95)

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1
Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and
Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3
A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of
Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
A/T Diagnosis General Description ..................... 5A-7
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10
Transmission Control Module (TCM) Wiring
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Location ......................................... 5A-14
Electronic Shift Control System Components
Location .......................................................... 5A-14
Diagnostic Information and Procedures .......... 5A-16
A/T System Check ............................................ 5A-16
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-19
Transmission Warning Light Check (Non-
Euro-OBD model) ........................................... 5A-19
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-21
DTC Clearance ................................................. 5A-22
Fail-Safe Table .................................................. 5A-22
Scan Tool Data ................................................. 5A-24
A/T Basic Check ............................................... 5A-27
Road Test ......................................................... 5A-27
Manual Road Test ............................................. 5A-30
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-31
Time Lag Test ................................................... 5A-32
Line Pressure Test ............................................ 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ................................... 5A-34Transmission Warning Light Circuit Check –
Light Remains “ON” at Ignition Switch ON
(Non-Euro-OBD Model)................................... 5A-41
Transmission Warning Light Circuit Check –
Light Does Not Come “ON” at Ignition Switch
ON (Non-Euro-OBD Model)............................ 5A-41
DTC P0602: Control Module Programming
Error ................................................................ 5A-42
DTC P0705: Transmission Range Sensor
Circuit Malfunction (PRNDL Input) .................. 5A-42
DTC P0707: Transmission Range Sensor
Circuit Low ...................................................... 5A-44
DTC P0711: Transmission Fluid Temperature
Sensor “A” Control Range / Performance ....... 5A-46
DTC P0712: Transmission Fluid Temperature
Sensor Circuit Low .......................................... 5A-47
DTC P0713: Transmission Fluid Temperature
Sensor Circuit High ......................................... 5A-48
DTC P0717: Input / Turbine Speed Sensor
Circuit Malfunction........................................... 5A-50
DTC P0722: Output Speed Sensor (VSS)
Circuit No Signal ............................................. 5A-51
DTC P0741 / P0742: TCC Circuit
Performance or Stuck OFF / TCC Circuit
Stuck ON ......................................................... 5A-53
DTC P0751 / P0752 / P0756 / P0757: Shift
Solenoid Malfunction ....................................... 5A-54
DTC P0787: Shift / Timing Solenoid Control
Circuit Low ...................................................... 5A-55
DTC P0788: Shift / Timing Solenoid Control
Circuit High...................................................... 5A-57
DTC P0961: Pressure Control Solenoid “A”
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure Control Solenoid
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure Control Solenoid
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid-A (No.1)
Control Circuit Low / Shift Solenoid-B (No.2)
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid-A (No.1)
/ Shift Solenoid-B (No.2) Control Circuit High .. 5A-66
DTC P1702: Internal Control Module Memory
Check Sum Error............................................. 5A-68