Transfer Assembly Disassembly and Reassembly
Transfer Assembly Disassembly and ReassemblyDisassembly
Reference: Transfer Assembly Dismounting and Remounting:Motor-Shift Type (Transfer with Shift Actuator)
1) Remove snap ring (1) and washer (2).
2) Remove front output flange (1) and O-ring from front output shaft. Use special tool if it is hard to remove.
Special Tool
(A): 09913-65135
(B): 09925-88210
3) Remove harness bracket (1) and damper (2).
4) Remove center differential lock switch (1) and 4L/N switch (2).
5) Remove transfer actuator assembly (3) and breather pipe (4).
6) Remove oil pump cover (1).
7) Remove oil pump inner rotor (1), outer rotor (2), oil strainer (4) and drive pin (3).
8) Remove front case (1) using plastic hammer.
9) Remove rear case bolts (1) and then separate center case (3) using special tool.
Special Tool
(A): 09912-34510
10) Remove knock pin (1) and oil pipe (2) from center case (4) and remove front oil seal No.1 (3) using flat end rod or the like, if necessary.
11) Remove needle bearings (1) from center case (2) using special tools, if necessary.
Special Tool
(A): 09925-98210
12) Remove needle bearing (1), snap ring (2), washer (3) and shim(s) (4) from rear output shaft (5).
13) Remove differential side gear No. 1 (1), center differential assembly (2) and differential side gear No. 2 (3) from rear output shaft.
14) Remove low gear (1) and needle bearing (2) from rear output shaft.
15) Remove needle bearing (1), front drive clutch hub (2) and thrust washer (5) from rear output shaft.
16) Remove differential lock clutch sleeve (1) from rear output shaft (2).
17) Remove differential lock clutch hub (1) from rear output shaft (2).
18) Take out front drive sprocket (1), front output shaft assembly (2), drive chain (3) and needle bearing (4) from rear case (5) all at once.
19) Remove snap ring (1), and then remove rear output shaft assembly (2) from rear case (3).
20) Remove rear oil seal (1) from rear case (2) using flat end rod or the like, if necessary.
21) Remove input gear plate bolts (1) from front case (2).
22) Remove input gear assembly (1) and counter gear assembly (2) from front case (3) using plastic hammer.
23) Remove front oil seal No.2 (1) from front case (2) using flat end rod or the like, if necessary.
Reassembly
1) Install new front oil seal No.2 to front case (1) using special tool, and then apply grease to oil seal lip.
: Grease 99000-25011 (SUZUKI Super Grease A)
Special Tool
(A): 09913-85210
2) Install counter gear assembly (1) to front case (2), and then install input gear assembly (3).
NOTE:
Install input gear plate (4) so as not to hit counter gear assembly.
3) Tighten new input gear plate bolts (1) to specified torque.
Tightening torque
Input gear plate bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
4) Install new rear oil seal (1) to rear case (2) using special tool as shown in figure, and then apply grease to oil seal lip.
"A": Grease 99000-25011 (SUZUKI Super Grease A)
Distance between case and oil seal "a"
: 3.5 - 4.5 mm (0.138 - 0.177 in.)
Special Tool
(A): 09913-70123
5) Install rear output shaft assembly (1) to rear case (2), and then install snap ring (3).
6) Install front drive sprocket (1), front output shaft assembly (2), drive chain (3) and needle bearing (4) into rear case (5).
7) Install differential lock clutch hub (1) into front drive sprocket (2).
8) Install differential lock clutch sleeve (1) to rear output shaft (2) as shown in figure.
9) Install thrust washer (3), front drive clutch hub (2) and needle bearing (1) to rear output shaft.
10) Install needle bearing (2) and low gear (1) to rear output shaft.
11) Install differential side gear No. 2 (3), center differential assembly (2) and differential side gear No. 1 (1) to rear output shaft.
12) Install reduction shift sleeve (1) to rear output shaft (2).
13) Select shim (1) as follows.
a) Install shim, washer (2) and used snap ring (3) into rear output shaft (4).
b) Check clearance between shim and washer.
c) If clearance is out of specified value, select a suitable shim so that clearance become specified value.
Clearance between shim and washer
: 0 - 0.43 mm (0 - 0.017 in.)
14) Remove used snap ring, and then install new snap ring (2) and needle bearing (1) to rear output shaft (3).
15) Install needle bearing (1) to center case (2) using special tools as shown in figure.
Distance between case and needle bearing "a"
: 0 - 0.5 mm (0 - 0.008 in.)
Special Tool
(A): 09925-98210
16) Install oil pipe (1) and knock pin (2) into center case (3).
17) Install new front oil seal No.1 (4) into center case using special tool as shown in figure, and then apply grease to oil seal lip.
Distance between case and oil seal "a"
: 3.5 - 4.5 mm (0.138 - 0.177 in.)
"A": Grease 99000-25011 (SUZUKI Super Grease A)
Special Tool
(A): 09913-70123
18) Clean mating surface of both center case and rear case (1), apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, mate center case with rear case and then tighten bolts (2) to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Rear case bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
19) Clean mating surface of both center case (1) and front case, apply sealant to center case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, mate front case (3) with center case and then tighten bolts (2) to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Rear case bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
20) Install oil strainer (1) to rear case (2).
Tightening torque
Strainer bolt (a): 10 Nm (1.0 kg-m, 7.5 lbf-ft)
21) Install oil pump inner rotor (3), outer rotor (4) and drive pin (5) to rear case (6).
22) Clean mating surface of oil pump cover (1) and rear case (2), apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolts (3) to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Oil pump cover bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
23) Clean mating surface of control cover (1) and center case (2), apply sealant to center case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, confirm the each fork of control cover is in groove of the sleeve, mate control cover with center case and then tighten control cover bolts (3) to which thread lock cement has been applied and control cover dowel bolts (4) to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No.1217G)
"B": Thread lock cement 99000-32110 (Thread Lock Cement Super 1322)
Tightening torque
Control cover bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
Control cover dowel bolt (b): 23 Nm (2.3 kg-m, 17.0 lbf-ft)
24) Install center differential lock switch (1), 4L/N switch (2) and breather pipe (3).
Tightening torque
Center differential lock switch (a): 20 Nm (2.0 kg-m, 14.5 lbf-ft)
4L/N switch (b): 20 Nm (2.0 kg-m, 14.5 lbf-ft)
25) Install harness bracket (1) and damper (2).
Tightening torque
Harness bracket bolt (a): 8.0 Nm (0.82 kg-m, 6.0 lbf-ft)
Damper bolt (b): 50 Nm (5.1 kg-m, 37.0 lbf-ft)
26) Install new O-ring (2) and front output flange (1) to front output shaft.
27) Install washer (3) and snap ring (4).
