SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-153
48) Install transaxle rear cover assembly on transaxle
case.
49) Install hook (2) to location shown in figure.
50) Tighten rear cover bolts (1).
Tightening torque
Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
51) Install fluid reservoir LH plate (1).
Tightening torque
Fluid reservoir LH plate bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
52) After applying A/T fluid to new governor apply No.2
gasket (1), install it to transaxle case.53) After applying A/T fluid to differential assembly (1)
and countershaft assembly (2), install them to
transaxle case.
54) After applying A/T fluid to direct clutch hub (1), install
it to planetary gear assembly.
55) After applying A/T fluid to input shaft rear thrust
bearing (1) and thrust bearing race (2), install them
into direct clutch hub (3).
56) After applying A/T fluid to input shaft front thrust
bearing (1), install it to direct clutch assembly (2).
I3RM0B510068-01
I2RH0B510303-01
I2RH0B510304-01
1
2
I4RS0A510036-01
I2RH0B510306-01
I2RH0B510307-01
I2RH0B510308-01

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 5A-156 Automatic Transmission/Transaxle:
68) Install new O-rings to each accumulator piston and
apply A/T fluid to them.
Accumulator O-ring dimension
NOTE
Make sure that O-rings are not twisted or
caught when installing.

69) Install B1, C1, C2 accumulator pistons and springs.
Accumulator piston identification
Accumulator spring identification
70) After applying A/T fluid to cooler check valve (1) and
spring (2), install them to transaxle case (3).
71) After applying A/T fluid to new governor apply No.1
gasket (1), install it to transaxle case. O-ring nameInside
diameterSection
diameter
Large B1 accumulator O-ring (2)
Large C1 accumulator O-ring (2)
Large C2 accumulator O-ring (2)
– Above three O-rings are same.29.4 mm
(1.16 in.)2.6 mm
(0.10 in.)
Small B1 accumulator O-ring (4)19.7 mm
(0.78 in.)2.6 mm
(0.10 in.)
Small C1 accumulator O-ring (6)
Small C2 accumulator O-ring (6)
– Above two O-rings are same.21.8 mm
(0.86 in.)2.6 mm
(0.10 in.)
Piston nameIdentification as
embossed letters on
piston
B1 accumulator piston (3) SB-1
C1 accumulator piston (5) SC-1
C2 accumulator piston (8) SC-2
Spring nameColor of identification
paint
B1 accumulator No.2
spring (1)Pink
C1 accumulator No.2
spring (7)Blue
C2 accumulator No.2
spring (9)Light green
I2RH0B510318-01
I2RH0B510319-01
I2RH0B510320-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-157
72) After applying A/T fluid to new O-ring, fit it to valve
body harness connector (3), then install valve body
harness to transaxle case.
CAUTION!
When put valve body harness (1) into
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow entrance of case.
Careless sensor treatment might cause
sensor malfunction.

Tightening torque
Valve body harness connector bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
73) Install manual valve rod (1) to manual valve lever (3)
and then install valve body assembly (2) to transaxle
case.
74) Tighten valve body bolts to specified torque.
Tightening torque
Valve body bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)Valve body bolt length
75) Connect solenoid connectors to solenoid valves
identifying their installing positions by wire colors,
and install transmission fluid temperature sensor to
its clamp.
Solenoid valve coupler specification
I2RH0B510321-01
I2RH0B510322-01
Bolt Length “a” Pieces
A (1) 20 mm (0.79 in.) 6
B (2) 28 mm (1.10 in.) 5
C (3) 49 mm (1.93 in.) 1
D (4) 36 mm (1.42 in.) 1
E (5) 40 mm (1.58 in.) 1
Solenoid valve coupler Wire color
Shift solenoid valve-A (No.1) (1) White
Shift solenoid valve-B (No.2) (2) Black
Timing solenoid valve (3) Yellow
TCC solenoid valve (4)Light green /
Brown
Pressure control solenoid valve (5) Gray / Green
Transmission fluid temperature
sensor (6)Orange
I2RH0B510323-01
1 4
6
3
2
5
I5RW0C510067-02

Downloaded from www.Manualslib.com manuals search engine 5A-158 Automatic Transmission/Transaxle:
76) Install oil strainer assembly (1).
Tightening torque
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
77) Install oil cleaner magnets (1) in oil pan (2).
NOTE
If metal particles are attached to the magnets,
clean them before installing.

78) Install new oil pan gasket (1) between transaxle case
and oil pan (2).
79) Tighten oil pan bolts to specified torque diagonally
and little by little.
Tightening torque
Oil pan bolt (a): 7.0 N·m (0.7 kgf-m, 5.0 lb-ft)80) After applying A/T fluid to new O-rings, fit it to fluid
cooler pipe unions (1). Then install fluid cooler pipe
unions to transaxle case.
Tightening torque
Fluid cooler pipe union (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
81) Install new gaskets (2) and then install fluid cooler
pipes.
Tightening torque
Fluid cooler pipe union bolt (b): 35 N·m (3.5 kgf-
m, 25.5 lb-ft)
Fluid cooler pipe bracket bolt (c): 10 N·m (1.0
kgf-m, 7.5 lb-ft)
82) After applying A/T fluid to new O-ring, fit it to fluid
filler tube. Then install fluid filler tube to transaxle
case.
Tightening torque
Fluid filler tube bolt (d): 10 N·m (1.0 kgf-m, 7.5
lb-ft)
I2RH0B510325-01
I2RH0B510326-01
I2RH0B510327-01
(d)
1, (a)2 (b)
(c)
I5RW0C510068-01

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 5A-160 Automatic Transmission/Transaxle:
94) Install manual select lever (1).
Tightening torque
Manual select lever nut (a): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
95) Install engine mounting LH bracket (1). Tighten
engine mounting LH bracket bolts and nut to
specified torque referring to “Engine Mountings
Components in Section 1D”.
96) Install torque converter (3) noting the following
points.
CAUTION!
• Before installing converter, make sure that
its pump hub portion is free from nicks,
burrs or damage which may cause oil seal
to leak.
• Be very careful not to drop converter on oil
pump gear. Damage in gear, should it
occur, may cause a critical trouble.

• Install torque converter aligning grooves (1) of
torque converter and projection (2) of oil pump
drive gear.
• Install torque converter, using care not to damage
oil seal of oil pump.
• After installing torque converter, check that
distance “a” is within specification.
Torque converter installing position
“a”: More than 19.9 mm (0.783 in.)
• Check torque converter for smooth rotation.
• Apply grease around cup (6) at the center of
torque converter.
“C”: Grease 99000–25011 (SUZUKI Super
Grease A)
1(a)I2RH0B510335-01
1
I5RW0C510058-01
4. Flange nut
5. Torque converter housing
I2RH0B510337-01

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
) / )) / )