Fifth Gear Disassembly And Reassembly - Suzuki SX4 Service Manual
Hide thumbs
Also See for SX4:
- Owner's manual (47 pages) ,
- Owner's manual (16 pages) ,
- Owner's manual (18 pages)
Table of Contents
Advertisement
10. Oil drain plug
: Apply sealant 99000-31260 to all around thread part of plug.
11. Oil gutter bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
12. Left case plate bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
13. Side cover bolts
14. Transaxle case bolts
15. 5th speed synchronizer ring
16. 5th speed synchronizer lever
17. 5th speed sleeve & hub
18. Circlip
19. Bearing set shim
20. Countershaft 5th gear
21. Countershaft nut
: After tightening nut to specified torque, caulk nut securely.
Fifth Gear Disassembly and Reassembly
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.
3
2
1
31. Reverse shaft bolt
32. Washer
33. Oil seal
34. Outer race
35. Shim
36. Oil gutter
5) Unfasten caulking of countershaft nut (2), install
S7RW0A5206015
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.
I4RH01520015-01
Manual Transmission/Transaxle:
: Apply sealant 99000-31260 to thread part of bolt.
: Apply SUZUKI SUPER GREASE A
99000-25010 to Oil seal lip.
: 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
: 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
: Do not reuse.
: Apply transaxle oil.
1
5B-17
(A)
2
I4RH01520016-01
I4RH01520017-01
Advertisement
Chapters
Table of Contents
Troubleshooting
Need help?
Do you have a question about the SX4 and is the answer not in the manual?
Questions and answers
Adjust throttle motor
The idle speed on a Suzuki SX4 should be controlled by the Idle Air Control Valve (IACV) rather than adjusting the idle screw on the throttle body, as the screw is factory set. Before using compressed air in the idle-air-bypass passages, the IACV should be removed to prevent damage to its delicate mechanism. If there is an issue with idle speed, checking the IACV function and referring to the SX4 service manual is recommended.
This answer is automatically generated
I have an issue of crank but not starting When I scan it brought this codeU0100 Which means no communication thou crank sensor wire was cut off but it was fix back What could be wrong and what could be the solution,
increasing revs when changing gears
The Suzuki SX4 may have increasing revs when changing gears due to its drive-by-wire system and the difference in final drive ratios between the manual (4.41) and automatic (2.81) transmissions. This difference causes high cruising RPMs in the manual version and sluggishness in the automatic. Additionally, if the revs climb while going uphill, it may be due to the transmission downshifting or kicking out of overdrive. Other possible causes include low transmission fluid, abuse, or a faulty transmission design.
This answer is automatically generated
My heater stopped working the blower **** is good, control unit ?
Possible issues with the heater in a Suzuki SX4 if the blower is working but the heater is not include:
1. Incorrect Temperature Output
- Temperature control cable broken or bent (non-A/C and manual A/C) → Check the temperature control cable.
- Temperature selector faulty (non-A/C and manual A/C) → Check the temperature selector.
- Incorrect installation of the temperature control cable (non-A/C and manual A/C) → Check and adjust the position as necessary.
- Temperature control door assembly broken → Repair the temperature control door assembly.
- Air ducts clogged → Repair air ducts.
- Heater core leaked or clogged → Replace the heater core.
- Heater hoses leaked or clogged → Replace heater hoses.
- Thermostat faulty → Check the thermostat.
- Temperature control actuator faulty (auto A/C) → Check the temperature control actuator.
- HVAC control module faulty (auto A/C) → Check the HVAC control module.
- Wiring or grounding faulty (auto A/C) → Repair as necessary.
2. Other Possible Causes
- Air flow control cable broken or bent → Check the air flow control cable.
Checking and addressing these components should help identify and resolve the heater issue.
This answer is automatically generated