Manual Transmission/Transaxle - Suzuki 2006 SX4 Service Manual

5-ii Table of Contents
DTC P1723: Range Select Switch
Malfunction......................................................5A-68
DTC P1878: Torque Converter Clutch
Shudder .......................................................... 5A-69
DTC P2762: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
Range / Performance ......................................5A-70
DTC P2763: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
High................................................................. 5A-72
DTC P2764: Torque Converter Clutch (TCC)
Circuit Pressure Control Solenoid Control
Circuit Low ......................................................5A-74
DTC U0073: Control Module Communication
Bus Off ............................................................5A-76
DTC U0100: Lost Communication with ECM /
PCM "A" .......................................................... 5A-76
Inspection of TCM and Its Circuits .................... 5A-76
TCM Power and Ground Circuit Check............. 5A-80
Brake Interlock System Inspection.................... 5A-81
Repair Instructions ............................................5A-82
Learning Control Initialization............................5A-82
A/T Fluid Level Check ....................................... 5A-82
A/T Fluid Change .............................................. 5A-83
Select Lever Components................................. 5A-84
Select Lever Assembly Removal and
Installation ....................................................... 5A-84
Select Lever Knob Installation........................... 5A-84
Select Lever Inspection.....................................5A-85
"3" Position Switch Inspection ........................... 5A-85
Shift Lock Solenoid Inspection .......................... 5A-85
Shift Lock Solenoid Replacement .....................5A-85
Select Cable Components ................................ 5A-86
Select Cable Removal and Installation ............. 5A-86
Select Cable Adjustment...................................5A-86
Key Interlock Cable Removal and Installation... 5A-87
Transmission Range Sensor Inspection and
Adjustment ......................................................5A-89
Output Shaft Speed Sensor (VSS) Removal
and Installation ................................................5A-90
Output Shaft Speed Sensor (VSS) Inspection ..5A-90
Input Shaft Speed Sensor Removal and
Installation ....................................................... 5A-91
Input Shaft Speed Sensor Inspection................ 5A-91
Transmission Fluid Temperature Sensor
Removal and Installation................................. 5A-91
Transmission Fluid Temperature Sensor
Inspection........................................................ 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation ....................................................... 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Inspection..................5A-94
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid)
Removal and Installation................................. 5A-95
Pressure Control Solenoid Valves Inspection ... 5A-96
Transmission Control Module (TCM)
Removal and Installation................................. 5A-97
A/T Relay Inspection .........................................5A-97
Differential Side Oil Seal Replacement .............5A-98
A/T Fluid Cooler Hoses Replacement ...............5A-98
Automatic Transaxle Unit Components.............5A-99
Automatic Transaxle Unit Dismounting and
Remounting...................................................5A-100
Automatic Transaxle Assembly Components .5A-102
Automatic Transaxle Unit Disassembly...........5A-104
Oil Pump Assembly Components ...................5A-116
Oil Pump Assembly Disassembly and
Reassembly ..................................................5A-116
Oil Pump Assembly Inspection .......................5A-117
Direct Clutch Assembly Components..............5A-119
Direct Clutch Assembly Preliminary Check .....5A-119
Direct Clutch Assembly Disassembly and
Reassembly ..................................................5A-120
Direct Clutch Assembly Inspection..................5A-122
Forward and Reverse Clutch Assembly
Components..................................................5A-123
Forward and Reverse Clutch Assembly
Preliminary Check .........................................5A-123
Forward and Reverse Clutch Assembly
Disassembly and Reassembly ......................5A-124
Forward and Reverse Clutch Assembly
Inspection......................................................5A-127
2nd Brake Piston Assembly Components.......5A-128
2nd Brake Piston Assembly Disassembly and
Reassembly ..................................................5A-128
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Components...........5A-129
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Disassembly and
Reassembly ..................................................5A-130
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Inspection...............5A-131
Countershaft Assembly Components..............5A-132
Countershaft Assembly Disassembly and
Reassembly ..................................................5A-132
Valve Body Assembly Components ................5A-133
Valve Body Assembly Disassembly and
Reassembly ..................................................5A-134
Differential Assembly Components .................5A-135
Differential Assembly Disassembly and
Reassembly ..................................................5A-136
Differential Assembly Inspection .....................5A-137
Torque Converter Housing Disassembly and
Reassembly ..................................................5A-138
Transaxle Case Disassembly and
Reassembly ..................................................5A-140
Automatic Transaxle Unit Inspection and
Adjustment ....................................................5A-141
Automatic Transaxle Unit Assembly ...............5A-144
Specifications ...................................................5A-161
Tightening Torque Specifications....................5A-161
Special Tools and Equipment .........................5A-162
Recommended Service Material .....................5A-162
Special Tool ....................................................5A-162
Manual Transmission/Transaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction ..........................5B-1