automatic transmission fluid SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 5A-126 Automatic Transmission/Transaxle:
• Apply A/T fluid to forward clutch separator plates (1),
discs (2) and retaining plate (3).
• Install forward clutch separator plates (1), discs (2)
and retaining plate (3), then snap ring (4) to forward
clutch drum.
• Install forward clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.• Measure forward clutch piston stroke in the same
manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
forward clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Available forward clutch retaining plate thickness
• Install reverse clutch cushion plate (1) in correct
direction as shown in figure.
• Apply A/T fluid to reverse clutch cushion plate (1),
reverse clutch separator plate (2), discs (3) and
retaining plate (4).
• Install reverse clutch cushion plate (1), reverse clutch
separator plate (2), discs (3), retaining plate (4) and
then snap ring (5) to intermediate shaft subassembly.
[A]: Correct [B]: Incorrect
4
1 2 3
I5RW0C510062-01
I2RH0B510188-01
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.1 mm (0.122 in.) 5
3.2 mm (0.126 in.) 2
3.3 mm (0.130 in.) 6
3.4 mm (0.134 in.) 3
3.5 mm (0.138 in.) 7
3.6 mm (0.142 in.) 4
1. Oil hole
I2RH0B510177-02
I3RM0B510062-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-127
• Install reverse clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
• Measure reverse clutch piston stroke in the same
manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
reverse clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
Available reverse clutch retaining plate thickness
Forward and Reverse Clutch Assembly
Inspection
S6RW0D5106042
Clutch, Discs, Separator Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated or discolored,
replace all discs.
• Before assembling new discs, soak them
in A/T fluid for at least two hours.

Forward Clutch Return Spring Subassembly
Measure free length of forward clutch return spring.
Forward clutch return spring free length
24.04 mm (0.946 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

[A]: Correct [B]: Incorrect
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
3.6 mm (0.142 in.) 4
I2RH0B510190-01
I2RH0B510191-01
I2RH0B510192-01
I2RH0B510193-01

Downloaded from www.Manualslib.com manuals search engine 5A-128 Automatic Transmission/Transaxle:
Forward Clutch Piston Lip and Forward Clutch
Balancer Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.Forward Clutch Drum Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
2nd Brake Piston Assembly ComponentsS6RW0D5106043
2nd Brake Piston Assembly Disassembly and
Reassembly
S6RW0D5106044
Disassembly
1) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm
2,
57 – 113 psi) to oil hole (1) of 2nd brake cylinder (3)
to remove 2nd brake piston (2).
I2RH0B510194-01
I2RH0B510195-01
I2RH0B510196-01
1. 2nd brake cylinder 4. Outer O-ring
2. 2nd brake piston : Apply automatic transaxle fluid.
3. Inner O-ring : Do not reuse.
I2RH0B510197-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-129
2) Remove inner O-ring (1) and outer O-ring (2).Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new O-rings. Apply A/T fluid to the O-rings,
before installation.
• Install 2nd brake piston (1) to which A/T fluid is
applied to 2nd brake cylinder (2).
Do not damage O-ring when installing 2nd brake
piston.
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly ComponentsS6RW0D5106045
I2RH0B510198-01
I2RH0B510199-01
I5RW0C510063-01
1. Snap ring 5. O/D and 2nd coast brake piston 9. Rear cover plug O-ring
2. O/D and 2nd coast brake return spring subassembly 6. Rear cover seal ring : Apply automatic transaxle fluid.
3. O/D and 2nd coast brake piston front O-ring 7. Transaxle rear cover : Do not reuse.
4. O/D and 2nd coast brake piston rear O-ring 8. Rear cover plug : 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-131
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Use new seal rings and O-rings. Apply A/T fluid to
seal rings and O-rings before installation.
• Tighten rear cover plugs to specified torque.
Tightening torque
Rear cover plug: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
• Before installing rear cover seal ring, apply A/T fluid to
ring.
First, tighten seal ring to 5 mm (0.197 in.), then install
seal ring.
• Do not open rear cover seal ring too wide to attach.
• Do not damage O/D and 2nd coast brake return
spring subassembly and piston by pressing in O/D
and 2nd coast brake return spring subassembly
passing through its original installing position over 1.0
mm (0.039 in.).
Special tool
(A): 09926–96030
(B): 09946–06710Transaxle Rear Cover (O/D and 2nd Coast Brake
Piston) Assembly Inspection
S6RW0D5106047
O/D and 2nd Coast Brake Return Spring
Subassembly
Measure free length of O/D and 2nd coast brake return
spring subassembly.
Free length of O/D and 2nd coast brake return spring
subassembly
“a”: 18.99 mm (0.748 in.)
NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.

Transaxle Rear Cover Bush
Measure transaxle rear cover bush bore by using special
tool.
If measured transaxle rear cover bush bore is out of
specifications, replace transaxle rear cover with new
one. In replacement, intermediate shaft subassembly
also needs to be checked. Replace intermediate shaft
subassembly, if necessary.
Special tool
(A): 09900–20605
Transaxle rear cover bush bore
Standard: 13.94 – 13.96 mm (0.549 – 0.550 in.)
1. Transaxle rear cover
1. Transaxle rear cover
I2RH0B510206-01
I2RH0B510201-01
I2RH0B510207-01
I2RH0B510208-01

Downloaded from www.Manualslib.com manuals search engine 5A-132 Automatic Transmission/Transaxle:
Countershaft Assembly ComponentsS6RW0D5106048
Countershaft Assembly Disassembly and
Reassembly
S6RW0D5106049
Disassembly
1) Remove countershaft LH bearing (1) and reduction
driven gear (2) at once by using special tool and
hydraulic press.
Special tool
(A): 09925–982212) Remove countershaft RH bearing (1) by using
special tools.
Special tool
(A): 09913–61510
(B): 09926–58010
Reassembly
1) Install new countershaft RH bearing (1) by using
special tool and hydraulic press.
Special tool
(A): 09913–84510
NOTE
Replace countershaft RH bearing together
with bearing cup as a set.

2) Install reduction driven gear (1) with special tools
and hydraulic press.
Special tool
(A): 09913–84510
(B): 09925–88210
1. Countershaft RH bearing 5. Bearing cap
2. Countershaft 6. Countershaft bearing shim
3. Countershaft LH bearing : Apply automatic transaxle fluid.
4. Reduction driven gear : Do not reuse.
I2RH0B510209-01
I2RH0B510210-01
I2RH0B510211-01
I2RH0B510212-01
I2RH0B510213-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-133
3) Install countershaft LH bearing (1) with special tools
and hydraulic press.
Special tool
(A): 09913–84510
(B): 09925–88210
Valve Body Assembly ComponentsS6RW0D5106050
I2RH0B510214-01
I4RS0A510044-01
1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid.
2. Shift solenoid valve-A (No.1) 7. Valve body assembly : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Shift solenoid valve-B (No.2) 8. Manual valve : Do not reuse.
4. TCC pressure control solenoid valve 9. Solenoid lock plate
5. Timing solenoid valve 10. O-ring

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-135
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Shift solenoid valve-A and -B are identical
• After applying A/T fluid to new O-rings, fit them to
solenoid valves, then install solenoid valves to valve
body.
• Tighten solenoid valve bolts to specified torque
Tightening torque
Solenoid valve bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Solenoid valve bolt specification
Differential Assembly ComponentsS6RW0D5106052
Bolt Length “a” Pieces
A (1) 49 mm (1.93 in.) 5
B (2) 20 mm (0.79 in.) 1
C (3) 60 mm (2.36 in.) 1
1
1 1
3
2
"a"
I4RS0A510046-01
I5RW0C510064-01
1. Differential side RH bearing 5. Side bearing shim : Apply automatic transaxle fluid.
2. Output shaft speed sensor (VSS) drive gear 6. Final gear bolt : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
3. Differential case subassembly 7. Side bearing cup : Do not reuse.
4. Final gear 8. Differential side LH bearing

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-137
2) As shown in figure, facing groove (2) side upward,
install final driven gear (1) to differential case.
3) Tighten final gear bolts (1) to specified torque.
NOTE
To avoid rust, apply A/T fluid to final driven
gear after installation.

Tightening torque
Final gear bolt (a): 78 N·m (7.8 kgf-m, 56.5 lb-ft)
4) After applying A/T fluid to output shaft speed sensor
(VSS) drive gear (1), install output shaft speed
sensor drive gear.
5) Install new differential side RH bearing (1) by using
special tool and hydraulic press.
NOTE
Replace differential side RH bearing together
with bearing cup as a set.

Special tool
(A): 09913–701236) Install new differential side LH bearing (1) by using
special tool and hydraulic press.
NOTE
Replace differential side LH bearing together
with bearing cup as a set.

Special tool
(A): 09913–70123
Differential Assembly InspectionS6RW0D5106054
1) Hold differential case subassembly with soft jawed
vice and set special tools as shown.
Special tool
(A): 09900–20607
(B): 09900–20701
2) Measure differential gear thrust play.
Differential gear thrust play
Standard: 0.06 – 0.22 mm (0.002 – 0.009 in.)
3) If thrust play is out of specification, replace
differential case subassembly.
2. Final driven gear
I2RH0B510230-01
I2RH0B510231-01
I2RH0B510232-01
I2RH0B510233-01
I2RH0B510234-01
I2RH0B510235-01

Downloaded from www.Manualslib.com manuals search engine 5A-138 Automatic Transmission/Transaxle:
Torque Converter Housing Disassembly and
Reassembly
S6RW0D5106055
Disassembly
1) Remove fluid reservoir RH plate (1) and lubrication
tube clamp (2).
2) Remove lubrication LH tube (1) and RH tube (2).
NOTE
Do not bend lubrication tube with excessive
force.

3) Remove differential side oil seal (1).4) Remove countershaft RH bearing cup by using
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
5) Remove differential side RH bearing cup by using
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
6) Remove torque converter case plugs (1).
I2RH0B510236-01
I2RH0B510237-01
I2RH0B510238-01
I2RH0B510239-01
I2RH0B510240-01
I2RH0B510241-01