Overhaul

Extension Case Disassembly and Reassembly

Extension Case Assembly Components

Extension Case Assembly Removal and Installation

Disassembly

1) Remove rear extension case and damper from front extension case.
2) Disassemble rear extension case (2) as follows, if necessary.
a) Remove oil seal (3) from rear extension case using flat end rod or the like.
b) Remove needle bearing (1) using special tools.
Special Tool

(A): 09913-76010

(B): 09944-66020





3) Remove intermediate shaft from front extension case.
4) Remove oil seal from front extension case using flat end rod or the like, if necessary.
5) Remove intermediate front bearing and/or intermediate rear bearing using hydraulic press (1) and bearing puller (2), if necessary.






Reassembly

Extension Case Assembly Inspection
1) Install intermediate front bearing (1) and/or intermediate rear bearing (2) using hydraulic press (3) and bearing puller (4).





2) Install oil seal (1) to front extension case (2) until it become flush with case using special tool, and then apply grease to oil seal lip.

NOTE:
When installing oil seal, face its spring side inward.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)

Special Tool

(A): 09951-46010





3) Install intermediate shaft with bearings to front extension case.
4) Assemble rear extension case (2) as follows.
a) Install needle bearing (1) to rear extension case until it become flush with case using special tool.
Special Tool

(A): 09913-75520





b) Install oil seal (1) to rear extension case (2) until it become flush with case using special tool, and then apply grease to oil seal lip.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)

Special Tool

(A): 09913-75510





5) Clean mating surfaces of front extension case and rear extension case (1), apply sealant to rear extension case as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate rear extension case with front extension case, and then tighten bolts to specified torque.

"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)

Tightening torque
Extension case bolt 23 Nm (2.3 kgf-m, 17.0 lbf-ft)





6) Install damper (1) to rear extension case (2) and tighten damper bolts (3) to specified torque.

Tightening torque
Damper bolts (a): 50 Nm (5.0 kgf-m, 36.5 lbf-ft)