check transmission fluid SUZUKI SX4 2006 1.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine 5A-90 Automatic Transmission/Transaxle:
3) Check that engine starts in “N” and “P” ranges but it
doesn’t start in “D”, “2”, “L” or “R” range. Also, check
that back-up lamp lights in “R” range.
If faulty condition cannot be corrected by adjustment,
disconnect transmission range sensor connector
and check that continuity exists as shown by moving
manual select lever.
Output Shaft Speed Sensor (VSS) Removal and
Installation
S6RW0D5106010
Removal
1) Disconnect negative cable at battery.
2) Disconnect output shaft speed sensor connector (2).
3) Remove output shaft speed sensor (VSS) (1) by
removing its bolt.
Installation
1) Apply A/T fluid to output shaft speed sensor O-ring.
2) Install output shaft speed sensor (VSS) (1) to A/T
case and tighten bolt to specified torque.
Tightening torque
Output shaft speed sensor (VSS) bolt (a): 13
N·m (1.3 kgf-m, 9.5 lb-ft)3) Connect output shaft speed sensor connector (2) to
output shaft speed sensor (VSS) (1).
4) Connect negative cable to battery.
Output Shaft Speed Sensor (VSS) InspectionS6RW0D5106011
1) Connect positive cable of 12 volt battery to “A”
terminal of sensor and ground cable to “C” terminal.
Then using voltmeter, check voltage between “B”
terminal and “C” terminal with output shaft speed
sensor (VSS) driven gear rotated.
If measured voltage (pulse signal) is not as
specified, replace sensor.
Output shaft speed sensor (VSS) output voltage
Pulse signal of alternating 0 – 1 V and 10 – 14 V
2) Check output shaft speed sensor (VSS) driven gear
(1) for wear.
Replace if necessary.
1 2
3
4
5
9
87
6
1
P
R
N
D
2
LTerminal No.
Sensor Position
23456789
I3RH0A510038-01
12I5RW0C510032-01
(a)
12
I5RW0C510033-01
I2RH0B510045-01
I2RH0B510046-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-91
Input Shaft Speed Sensor Removal and
Installation
S6RW0D5106012
Removal
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Remove input shaft speed sensor (1) by removing its
bolt.
Installation
1) Apply A/T fluid to input shaft speed sensor O-ring.
2) Install input shaft speed sensor (1) to A/T case and
tighten bolt to specified torque.
Tightening torque
Input shaft speed sensor bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
3) Connect input shaft speed sensor connector (2) to
input shaft speed sensor (1).
4) Connect negative cable to battery.
Input Shaft Speed Sensor InspectionS6RW0D5106013
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Check resistance between input shaft speed sensor
(1) terminals.
Input shaft speed sensor resistance
Standard: 560 – 680 Ω at 20 °C (68 °F)
Transmission Fluid Temperature Sensor
Removal and Installation
S6RW0D5106014
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove left side engine under cover.
4) With engine is cool, remove drain plug and drain A/T
fluid.
5) Install drain plug. Refer to “A/T Fluid Change”.
6) Remove A/T oil pan.
7) Remove oil strainer assembly.
8) Remove valve body assembly referring to
“Automatic Transaxle Unit Disassembly”.
CAUTION!
When pulling valve body harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

9) Remove valve body harness (1).
12
I5RW0C510034-01
12
(a)I5RW0C510035-01
12I5RW0C510036-01
I2RH0B510050-01

Downloaded from www.Manualslib.com manuals search engine 5A-92 Automatic Transmission/Transaxle:
Installation
Reverse removal procedure to install valve body
harness and valve body assembly noting the following
points.
• For details of valve body assembly and their
connectors installation, refer to “Automatic Transaxle
Unit Assembly”.
• For details of A/T oil pan installation, refer to
“Automatic Transaxle Unit Assembly”. Use new oil
pan gasket.
• Tighten valve body harness connector bolt to
specified torque.
Tightening torque
Valve body harness connector bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
• Pour A/T fluid and check fluid level according to
procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.Transmission Fluid Temperature Sensor
Inspection
S6RW0D5106015
Warm up transmission fluid temperature sensor (2).
Check resistance between terminals of valve body
harness connector (1). Thus make sure its resistance
decrease as its temperature increase.
Transmission fluid temperature sensor resistance
10 °C (50 °F): 5.8 – 7.1 kΩ
11 0 °C (230 °F): 231 – 263 Ω
145 °C (293 °F): 105 – 117 Ω
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation
S6RW0D5106061
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove left side engine under cover.
4) Remove drain plug and drain A/T fluid.
5) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
6) Remove A/T oil pan (1) and oil pan gasket (2).
I2RH0B510051-01
I2RH0B510052-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-95
Timing solenoid valve
CAUTION!
• Do not insert air gun against strainer
installed on inlet of solenoid valve too
deeply, when blowing air into solenoid
valve. If not, the strainer will be damaged.
• Be very careful as dust etc. does not enter
when solenoid valves are inspected.

• Check that solenoid valve (1) actuate with click sound
when battery voltage is conducted.
• When timing solenoid valve (1) is connected to battery
(2), confirm that timing solenoid valve is open
condition by blowing air (50 – 200 kPa, 0.5 – 2.0 kg/
cm
2, 7 – 28.5 psi) into solenoid valve as shown in
figure.
• When timing solenoid valve (1) is not connected to
battery (2), confirm that timing solenoid valve is close
condition by blowing air (50 – 200 kPa, 0.5 – 2.0 kg/
cm
2, 7 – 28.5 psi) into solenoid valve as shown in
figure.
NOTE
Do not fail to inspect with air to prevent
mistaken checking because return spring for
valve is not installed into solenoid valve.

Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid) Removal
and Installation
S6RW0D5106063
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove left side engine under cover.
4) Remove drain plug and drain A/T fluid.
5) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
6) Remove A/T oil pan (1) and oil pan gasket (2).
7) Remove oil strainer assembly (3).
8) Remove transmission fluid temperature sensor (1)
from sensor clamp.
9) Disconnect solenoid connectors (2).
I2RH0B510063-01
I2RH0B510054-01
2
1
I5RW0C510038-02

Downloaded from www.Manualslib.com manuals search engine 5A-96 Automatic Transmission/Transaxle:
10) Remove valve body assembly referring to
“Automatic Transaxle Unit Disassembly”.
11) Remove pressure control solenoid valve and TCC
pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC
pressure control solenoid valve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body assembly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves
and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “Automatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to
procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valves InspectionS6RW0D5106020
CAUTION!
• Be very careful as dust etc. does enter
when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)Operation Check
Check pressure control solenoid valves (Pressure
control solenoid and TCC pressure control solenoid)
operation in the either manner of the following.
Using regulated DC power supply
1) Connect pressure control solenoid valve (1) with
regulated DC power supply (2) as shown in figure.
2) Turn regulated DC power supply switch ON and
increase voltage of power supply keeping current
within 1.0 A.
3) Check for gradual movement of valve (3) in the
direction of arrow “A” as voltage is increased.
4) Check movement of valve (3) in the direction of
arrow “B” as voltage is decreased.
5) Turn power supply switch OFF.
CAUTION!
Do not pass current 1.0 A or more, or
pressure control solenoid is burned out.

Not using regulated DC power supply
1) Connect pressure control solenoid valve (1) to
battery (2) setting 21 W bulb (4) on the way as
shown in figure.
2) Check for movement of valve (3) in the direction of
arrow “A”.
3) Disconnect pressure control solenoid valve (1) from
battery (2) and check movement of valve (3) in the
direction of arrow “B” as shown in figure.
CAUTION!
Set 21 W bulb on the way, or pressure control
solenoid valve is burned out.

1
I2RH01510071-01
I2RH0B510064-01

Downloaded from www.Manualslib.com manuals search engine 5A-98 Automatic Transmission/Transaxle:
Differential Side Oil Seal ReplacementS6RW0D5106023
1) Lift up vehicle and drain automatic transaxle fluid.
2) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove differential side oil seal (1) by using special
tool.
Special tool
(A): 09913–50121
4) Apply grease to new differential side oil seal lips.
: Grease 99000–25030 (SUZUKI Super Grease C)
5) Install new differential side oil seals (1) by using
special tool.
Special tool
(A): 09913–75510
(B): 09913–75810
Differential side oil seal installing depth
Right side “a”: 13.2 – 14.2 mm (0.52 – 0.56 in.)
Left side “b”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
6) Insert drive shaft assembly and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
7) Pour A/T fluid referring to “A/T Fluid Change”.
A/T Fluid Cooler Hoses ReplacementS6RW0D5106027
The rubber hoses for the A/T fluid cooler should be
checked at specified interval. If replacing them, be sure
to note the following.
• to replace clamps at the same time
• to insert hose as far as its limit mark
• to clamp clamps securely
[A]: Right side [B]: Left side
(A)
1I5RW0A520006-02
“a” “b”
(B)[B] [A]
1
(A)
I5RW0C510042-01
1. Inlet hose (Outlet from A/T fluid cooler)
2. Outlet hose (Inlet to A/T fluid cooler)
2
1I5RW0C510049-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-106 Automatic Transmission/Transaxle:
16) Remove valve body harness (1).
CAUTION!
When pulling valve body harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

17) Remove governor apply No.1 gasket (1).
18) Remove cooler check valve (1) and spring (2).19) Remove accumulator pistons and springs.
To remove C2 (1), C1 (2) and B1 (3) accumulator
pistons and springs, position rag on pistons to catch
each piston. To remove pistons, force low-pressure
compressed air (1 kg/cm
2, 15 psi, 100 kPa, max) into
hole (4) as shown in figure, and pop each piston into
rag.
NOTE
Do not push accumulator pistons with
fingers or anything before removing them.
Pushing them may cause compressed fluid
in accumulator to spew out of hole and get to
your face and clothes.

I2RH0B510091-01
I2RH0B510092-01
I2RH0B510093-01
I2RH0B510094-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-117
Reassembly
1) Install new oil pump body oil seal (1).
Use special tool and hammer to install it, and then
apply grease to its lip portion.
Special tool
(A): 09913–85210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
2) Install driven gear and drive gear to oil pump body
after applying A/T fluid.
3) Install stator shaft assembly to oil pump body and
tighten 8 pump subassembly bolts (1) to
specification.
Tightening torque
Oil pump subassembly bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
4) After applying A/T fluid to new O-ring, install it to oil
pump body.
5) Check drive gear for smooth rotation by using torque
converter (1).Oil Pump Assembly InspectionS6RW0D5106034
1) Check body clearance of driven gear (1).
Push driven gear to one side of oil pump body (2).
Using a feeler gauge, measure clearance between
driven gear and body. If clearance exceeds its
standard value, replace oil pump assembly.
Clearance between oil pump driven gear and oil
pump body
Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.)
2) Check tip clearance of both drive and driven gears.
Using a feeler gauge, measure clearance between
drive and driven gear tips. If clearance exceeds its
standard value, replace oil pump assembly.
Tip clearance between oil pump drive gear and
oil pump driven gear
Standard: 0.07 – 0.15 mm (0.0028 – 0.0059 in.)
2. Oil pump body
I2RH0B510151-01
1, (a)
I4RS0A510042-01
1
I4RS0A510043-01
I2RH0B510154-01
I2RH0B510155-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-119
Direct Clutch Assembly ComponentsS6RW0D5106035
Direct Clutch Assembly Preliminary CheckS6RW0D5106036
Install direct clutch assembly (1) to oil pump assembly
(2) blow in air (400 – 800 kPa, 4 – 8 kg/cm2, 57 – 113
psi) through oil hole (3) of oil pump assembly with
special tool attached on upper surface of direct clutch
piston, and measure piston stroke of direct clutch.
If piston stroke exceeds specified value, disassemble,
inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
Direct clutch piston stroke
0.4 – 0.7 mm (0.016 – 0.027 in.)
I2RH0B510160-01
1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate
2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring
3. Input shaft subassembly 8. Shaft snap ring : Apply automatic transaxle fluid.
4. Inner O-ring 9. Direct clutch separator plate : Do not reuse.
5. Direct clutch piston 10. Direct clutch disc
I2RH0B510161-01