Safety Recall Campaign 4002 SX4 Select Lever Assembly Replacement (TS 12 01125R1)

Publication date: 2015-02-27
Reference number: TS 12 01125R1
Supersedes refnos: TS 12 01125

SAFETY RECALL CAMPAIGN 4002 SX4 SELECT LEVER ASSEMBLY REPLACEMENT

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 12 01125R1, Date of Issue: February 27, 2015

SUZUKI:

2010 - 2013 SX4

Superceded Bulletin(s): TS 12 01125R1, Date of Issue: January 8, 2015

CONDITION

The Select Lever moves from PARK to any other gear position without depressing the brake pedal.

CAUSE

The Select Lever lock mechanism becomes disabled when exessive force is applied to it.

CORRECTION

Replace the Select Lever Assembly.

Affected Vehicles: 2010 - 2013 SX4 models equipped with a Continuously Variable Transmission (CVT).

Revision: TS 12 01125R1 (Revised 2/27/15) includes instruction to evaluate the select lever knob for correct operation with the new Select Lever Assembly. Refer to Page 6.

Affected Departments: Management, Service, Parts

PARTS INFORMATION (CAMPAIGN 4002)

PARTS INFORMATION

Model	Part Number	Part Name	QTY	Notes
SX4	28100-54830-RX0	Lever Set, Select	1	Kit contains: 1) 28110-54L32 (Lever Assy, Select) 1) 28157-54L30 (Cap, Indicator)
SX4	28160-54L10-5PK	Knob Assy, Select Lever	As Required	In some cases it may be necessary to install a new select lever knob. Availability is limited. Orders will be fullfilled at a limit of 3 per order. Only place orders for vehicles requiring knob replacement.

WARRANTY CLAIM INFORMATION (CAMPAIGN 4002)

WARRANTY CLAIM INFORMATION

Labor Operation	Description	Failed Part Number	Complaint Code	Defect Code	Labor Time
Please refer to Service Campaign Bulletin SC-72 for claim submission instructions.

REMOVAL PROCEDURE

NOTE: Refer to the vehicle's Service Manual if necessary for any additional notes or procedure information related to this recall service.

Apply the parking brake and remove the cap (1) covering the manual release button.
Push on the shift lock manual release button and shift the select lever to Neutral.
Pull up to remove the rear console bezel (1), and disconnect the electrical connector(s) (2).
Pull up to remove the shift lever trim (1).
Pull up to remove the front console bezel (1).
Remove the left and right console side covers (1): A) Pull the console side cover in the direction of the arrow [a]. Release the claw (2), clip (3) and positioning pin (4).
Remove screws (1), then remove the console box (2).
Disconnect the interlock cable:
1. Position the select lever to the P range.
2. Press claws (3) of the interlock cam (2) and detach the interlock cable end (1).
3. Press the check hook and detach the casing cap (4) from the select lever bracket (5).
4. Disconnect the interlock cable (6).
Shift the select lever to the N range.
Detach the select cable end (1) from the select lever pin of the Select Lever Assembly. Then detach the casing cap (2) from the select lever bracket (3).
Remove the Select Lever Assembly:
1. Disconnect the select lever electrical connector (1) and clamp (2).
2. Remove the nuts (3), then remove the Select Lever Assembly (4).
Slide the select lever knob cover (A) down.
Remove the screws (1), then remove the select lever knob (2) and cover (3).
Disconnect the select lever lamp assembly (1) from the select lever indicator (2).
Detach the claws (3) of the select lever indicator from the Select Lever Assembly, then remove the select lever indicator.
Remove the lamp (1) from the socket.

SELECT LEVER KNOB EVALUATION FOR REUSE

Before the new Select Lever Assembly is installed, it is critical for the select lever knob to be evaluated for correct operation with the new Select Lever Assembly. Complete the following steps before installing the new Select Lever Assembly to the vehicle.

Using the select lever knob screws, install the knob onto the new Select Lever Assembly.
1. Pull and hold the shift lock release lever (1). While depressing the select lever release knob (2) slowly and softly, shift the select lever from P to N , and from N to P . If the select lever does not move smoothly or can not be shifted for any reason (notchy feeling, interference, stuck, etc.), replace the select lever knob with a new one.
2. Pull and hold the shift lock release lever (1). While depressing the select lever release knob (2) quickly and firmly, shift the select lever from P to N , and from N to P . If the select lever does not move smoothly or can not be shifted for any reason (notchy feeling, interference, stuck, etc.), replace the select lever knob with a new one.
Viewing from the passenger side of the Select Lever Assembly, pull the shift lock release lever (1) and move the select lever to line up the detent lock bar with the bottom edge of the gate. While depressing the select lever release knob (2), measure the clearance between the detent lock bar and the gate. If the clearance is not between 0.5mm to 2.0mm (0.02 in to 0.07 in) replace the select lever knob with a new one.

INSTALLATION PROCEDURE

NOTE: The manual mode switch (1) on the select lever assembly can be easily damaged if force is applied. Do not contact the manual mode switch during installation.

NOTE: Review the following special instructions before beginning the installation process. Then install the Select Lever Assembly in the reverse order of dissassembly.

Install the indicator lamp into the lamp socket of the new Select Lever Assembly.
Install the select lever indicator (3) onto the Select Lever Assembly (4) while inserting the tip of the shift lock solenoid release plate (1) into the hole (2).
Install the select lever cover and knob to the Select Lever Assembly.
Torque: 1.3 N.m (0.13 kgf-m, 1.0 lb-ft)
Install the Select Lever Assembly to the floor.
Torque: 13 N.m (1.3 kgf-m, 9.5 lb-ft)
Select Neutral when completing the following steps:
1. Install the casing cap (1) onto the select lever bracket (2).
2. Release the select cable lock plate (1) that blocks the lock piece (2). Then pull out the lock piece from the adjuster case (3) using pliers.
3. Apply grease (99000-25011) to point "A" of the select lever pin (1). Then fit the adjuster case (2) onto the select lever pin.
4. Push the lock piece (3) in the direction of the arrow [a].
5. Slide the lock plate (4) in the direction of the arrow [b] until it covers the claw (5).
6. Pull out the interlock cable lock piece (1) from the cable end (2).
7. Install the casing cap (1) to the select lever bracket (2).
8. Turn the ignition switch to the ACC position and connect the interlock cable end (3) to the interlock cam (4).
9. Push the lock button (5) into the interlock cable end until it clicks.
Install the console and verify for the following:
1. The select lever can be operated smoothly.
2. The select lever lamp illuminates when the clearance lights are turned on.
3. The engine starts in the P and N ranges, but does not start in any other range.
4. The back up lamps illuminate when the select lever is shifted to the R range.
5. The shift position indicator is consistent with the select lever position.
Check the key interlock function for proper operation as follows:
1. Shift the select lever to the P range and set the ignition switch to ACC .
2. Push the shift lock solenoid release and press the select lever button (1) and check that the ignition switch cannot be turned from the ACC to the LOCK position.
3. Release the select lever button. Check that the ignition switch can be turned from the LOCK to the ACC position.
Install the new manual release cap onto the select lever indicator cover.