Diagnostic Information And Procedures; Manual Transaxle Symptom Diagnosis; Repair Instructions; Manual Transaxle Oil Level Check - Suzuki SX4 Service Manual

Manual Transaxle Symptom Diagnosis

Condition
Gears slipping out of
mesh
Hard shifting
Noise

Manual Transaxle Oil Level Check

1) Lift up vehicle and check oil leakage. Repair leaky
point, if any.
2) Remove oil level / filler plug (1) and check oil
contamination and oil level is lower end of oil level /
filler plug hole (2).
If oil is excessive dirty or insufficient, replace oil or
pour specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
"A": Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lb-ft)

Diagnostic Information and Procedures

Possible cause
Worn shift fork shaft
Worn shift fork or synchronizer sleeve
Weak or damaged locating springs
Worn bearings on input shaft or
countershaft
Worn chamfered tooth on sleeve and
gear
Inadequate lubricant
Improper clutch pedal free travel
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve or gear Replace sleeve or gear
Worn gear shift control shaft joint bush
Distorted shift shaft
Broken gear shift / select control cables Replace
Inadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts

Repair Instructions

S7RW0A5206001
Manual Transmission/Transaxle:
Correction / Reference Item
Replace
Replace
Replace
Replace
Replace sleeve and gear
Replenish
Replace clutch arm or master cylinder
Replace
Replace clutch cover
Replace
Replace
Replace
Replenish
Replace
Replace
Replace
5B-5
S7RW0A5204001
I5RW0A520004-01