Sas SUZUKI SX4 2006 1.G Service Manual Online

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 5A-134 Automatic Transmission/Transaxle:
Valve Body Assembly Disassembly and
Reassembly
S6RW0D5106051
CAUTION!
When replacing pressure control solenoid
valve and/or TCC pressure control solenoid
valve, it is strictly required to replace it
together with valve body assembly as a set.
Replacing pressure control solenoid valve
and/or TCC pressure control solenoid valve
independently may cause excessive shift
shock.

Disassembly
1) Pull out manual valve (1).
2) Remove pressure control solenoid valve (1).
3) Remove TCC pressure control solenoid valve (1).4) Remove shift solenoid valve-A (1).
5) Remove shift solenoid valve-B (1).
6) Remove timing solenoid valve (1).
7) Remove temperature sensor clamp (1).
2. Solenoid lock plate
I2RH0B510216-01
I2RH0B510217-01
1
I4RS0A510045-01
I2RH0B510219-01
I2RH0B510220-01
I2RH0B510221-01
I2RH0B510222-01

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 5A-136 Automatic Transmission/Transaxle:
Differential Assembly Disassembly and
Reassembly
S6RW0D5106053
Disassembly
1) Remove final gear bolts (1), and then final gear (2).
2) Remove differential side RH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
3) Remove output shaft speed sensor (VSS) drive gear
(1).4) Remove differential side LH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
Reassembly
WARNING!
• When taking warmed final driven gear out
of vessel, use tongs or the like. Taking out
it with bare hand will cause severe burn.
• While installing warmed final driven gear,
use oven glove such as leather glove.
Picking up it with bare hand may cause
burn.

CAUTION!
Do not leave final driven gear in boiling water
for longer than 5 min. Overheating the gear
may cause strength reduction of gear.

1) Put final driven gear in water vessel, heat and
remove when it boils, then remove moisture.
NOTE
After removing moisture on final driven gear,
install final driven gear to differential case as
quickly as possible.

2. Differential case subassembly
I2RH0B510225-01
I2RH0B510226-01
I2RH0B510227-01
I2RH0B510228-01
I2RH0B510229-01

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

Downloaded from www.Manualslib.com manuals search engine 5A-140 Automatic Transmission/Transaxle:
Transaxle Case Disassembly and ReassemblyS6RW0D5106056
Disassembly
1) Remove differential side oil seal (1).
2) Remove countershaft LH bearing cup and shim with
special tools.
Special tool
(A): 09944–96011
(B): 09942–15511
3) Remove differential side LH bearing cup and shim
with special tools.
Special tool
(A): 09944–96011
(B): 09942–15511Reassembly
1) Using special tools, assemble shim and differential
side LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
2) Using special tools, assemble shim and countershaft
LH bearing cup.
NOTE
Use shim with same thickness as the
removed one.

Special tool
(A): 09924–74510
(B): 09944–88220
I2RH0B510247-01
I2RH0B510248-01
I2RH0B510249-01
(B) (A)
I3RM0B510065-01
(B)(A)
I3RM0B510066-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-15
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly
S6RW0D5206013
1) Push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12
in.) commercially available spring pin remover and
specified spring pin removers as shown bellow.
Special tool
(A): 09922–85811 4.5 mm
(B): 09925–78210 6.0 mm
2) Inspect component parts for wear, distortion or
damage. If any detect is found, replace detective
part with new one.
NOTE
• When driving in spring pins, prevent shaft
from being bent by supporting it with wood
block.
• Assemble 5th & reverse gear shift cam
with its pit and spring pin aligned.
• Make sure to select an appropriate spring
by identifying the painted colors to keep
gear shifting performance as designed.
– Low speed select spring - Light blue
– Reverse select spring - Pink

1. E-ring 8. Spring pin
2. Washer 9. Gear shift & select shaft
3. Reverse select spring 10. 5th & reverse gear shift cam
4. Gear shift interlock plate 11. Cam guide return spring
5. Ball 12. 5th & reverse gear shift cam guide
6. Gear shift interlock spring 13. Low speed select spring
7. Gear shift & select lever 14. Spring pin remover
I6RW0C520002-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-17
Fifth Gear Disassembly and ReassemblyS6RW0D5206015
Disassembly
1) Remove cover bolts and take off transaxle side
cover.
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using special tool, remove circlip (1).
Special tool
: 09900–06107
3) Remove shift fork shaft bolt (2).
4) Remove gear shift fork (3) and 5th gear all together.
Use gear puller for removal if spline fitting of hub is
tight.5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and
then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
10. Oil drain plug
: Apply sealant 99000-31260 to all around thread part of plug.31. Reverse shaft bolt
: Apply sealant 99000-31260 to thread part of bolt.
11. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.32. Washer
12. Left case plate bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.33. Oil seal
: Apply SUZUKI SUPER GREASE A
99000-25010 to Oil seal lip.
13. Side cover bolts 34. Outer race
14. Transaxle case bolts 35. Shim
15. 5th speed synchronizer ring 36. Oil gutter
16. 5th speed synchronizer lever : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
17. 5th speed sleeve & hub : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
18. Circlip: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
19. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
20. Countershaft 5th gear : Do not reuse.
21. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.: Apply transaxle oil.
32
1
I4RH01520015-01
(A)
2
1
I4RH01520016-01
I4RH01520017-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-19
7) Fit 5th gear shift fork (1) to sleeve (3) and hub (2)
assembly, and install them into input shaft and gear
shift shaft, aligning punch mark (4) with matching
mark (5) on input shaft.
8) Tighten shift fork shaft bolt (2) to which thread lock
cement has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Shift fork shaft bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-
ft)
9) Using special tool, install new circlip (1) to input shaft
(3).
Special tool
: 09900–0610710) Clean mating surface of both left case and side
cover (1), apply sealant to side cover as shown in
figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate it with left case, and
then tighten side cover bolts with specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Manual Transaxle Assembly Disassembly and
Reassembly
S6RW0D5206016
Disassembly
1) Remove left case plate bolts (1), and take off left
case plate (2).
I3RH0A520080-01
2, (a), “A”
13
I5RW0A520019-013. Input shaft
I5RW0A520020-01
I4RH01520018-01

Downloaded from www.Manualslib.com manuals search engine 5B-24 Manual Transmission/Transaxle:
16) Place left case plate (2) inserting its end in groove of
shift guide shaft (4) and then tighten bolts (1) to
which thread lock cement has been applied.
NOTE
After tightening bolts, make sure that
countershaft can be rotated by hand feeling
certain load.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Right Case Disassembly and ReassemblyS6RW0D5206017
Disassembly
1) Remove differential side oil seal from right case
referring to “Differential Side Oil Seal Replacement”,
if necessary.
2) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.3) Remove input shaft oil seal by using special tool, if
necessary.
Special tool
(A): 09913–75830
4) Pull out countershaft right bearing outer race by
using special tools, if necessary.
Special tool
(A): 09930–30104
(B): 09941–64511
Reassembly
1) Install input shaft oil seal facing its spring side
upward until it becomes flush with case surface. Use
special tool and hammer for installation and apply
grease to oil seal lip.
: Grease 99000–25011 (SUZUKI Super Grease A)
Special tool
(A): 09913–76010
3. Input shaft
5. Countershaft
I2RH01520087-01
2
1
I4RH01520024-01
(A)
I5RW0A520026-01
(A)
(B)
I5RW0A520027-01
(A)
I5RW0A520028-01