Suzuki 2006 SX4, Service Manual

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Table of Contents 5-iii
Specifications...................................................5A-142
Tightening Torque Specifications.................... 5A-142
Special Tools and Equipment .........................5A-143
Recommended Service Material..................... 5A-143
Special Tool .................................................... 5A-143
Manual Transmission/Transaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction .......................... 5B-1
Diagnostic Information and Procedures............5B-6
Manual Transaxle Symptom Diagnosis............... 5B-6
Repair Instructions ..............................................5B-6
Manual Transaxle Oil Level Check ..................... 5B-6
Manual Transaxle Oil Change ............................ 5B-7
Differential Side Oil Seal Replacement ............... 5B-8
Gear Shift Control Lever and Cable
Components...................................................... 5B-9
Gear Shift Control Lever and Cable Removal
and Installation................................................5B-10
Gear Select Control Cable Adjustment .............5B-10
Back Up Light Switch Removal and
Installation.......................................................5B-11
Back Up Light Switch Inspection....................... 5B-11
Manual Transaxle Unit Components................. 5B-12
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-13
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-14
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-15
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly........................ 5B-16
Manual Transaxle Assembly Components........ 5B-17
Fifth Gear Disassembly and Reassembly .........5B-18
Manual Transaxle Assembly Disassembly
and Reassembly .............................................5B-20
Right Case Disassembly and Reassembly ....... 5B-25
Left Case Disassembly and Reassembly.......... 5B-26
Input Shaft and Countershaft Components....... 5B-28
Input Shaft Disassembly and Reassembly........ 5B-29
Countershaft Disassembly and Reassembly .... 5B-32
Gear Shift Shaft Components ........................... 5B-36
5th and Reverse Gear Shift Shafts
Disassembly and Reassembly ........................5B-36
Gear Shift Shaft and Fork Inspection ................5B-36
Differential Components....................................5B-37
Differential Disassembly and Reassembly........5B-37
Specifications.....................................................5B-39
Tightening Torque Specifications......................5B-39
Special Tools and Equipment ...........................5B-40
Recommended Service Material .......................5B-40
Special Tool ......................................................5B-40
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch (Hydraulic Type) Construction .................5C-1
Diagnostic Information and Procedures............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-3
Clutch Pedal Inspection ......................................5C-3
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-4
Clutch Pedal Position (CPP) Switch Removal
and Installation ..................................................5C-4
Clutch Pedal Position (CPP) Switch
Inspection and Adjustment................................5C-5
Clutch Fluid Pipe and Hose Location ..................5C-5
Clutch Fluid Pipe Removal and Installation.........5C-6
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and
Installation .........................................................5C-6
Clutch Operating Cylinder Assembly
Removal and Installation...................................5C-7
Clutch Operating Cylinder Assembly
Inspection..........................................................5C-8
Clutch Cover, Clutch Disc and Flywheel
Components......................................................5C-8
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation...................................5C-9
Clutch Cover and Clutch Disc Inspection..........5C-11
Specifications.....................................................5C-11
Tightening Torque Specifications......................5C-11
Special Tools and Equipment ...........................5C-12
Recommended Service Material .......................5C-12
Special Tool ......................................................5C-12