3C
Transfer Assembly Disassembly and Reassembly
Reference: Transfer Assembly Dismounting and Remounting
Disassembly
1) Remove 4WD switch (1) and 4WD low switch (3), and then take out steel balls (2).
2) Remove VSS (1) from transfer.
3) Remove rear flange. To lock flange, use special tool.
With flange locked, remove flange nut (1).
Special Tool
(A) : 09930–40113
4) Remove case cover (1) and pinion gear (2), and then remove transfer shift actuator (3).
5) Remove 11 rear case bolts (1), and then separate front and rear cases using special tool.
NOTE:
To separate case, use special tool at 2 points in turn and make opening wider evenly.
Special Tool
(A) : 09912–34510
6) Pull out VSS rotor (1) and steel ball.
7) Remove front flanges (2). To lock flange, use special tool.
With flange locked, remove flange nut (1).
Special Tool
(A) : 09930–40113
8) Remove drive chain (2), input shaft (1), and sprocket output gear (3) as an assembly.
9) Remove needle roller bearings (1) and thrust bearing (2).
10) Remove counter gear assembly (1) from front case.
11) Remove output rear shaft assembly (3) with shift fork shaft No.1 (1) and No.2 (2) all at once.
12) Remove needle roller bearing (1) and synchronizer ring (2) from front case (3).
13) Remove output front shaft assembly (1) from front case (2).
14) Remove straight pin (1) and straight pin plug (3) from front case (2) as shown in the figure.
Reassembly
Reference: Transfer Inspection
1) Install output front shaft to front case.
2) Install output front flange, tighten new flange nut with flange locked by special tool.
Special Tool
(A) : 09930–40113
Tightening torque
Flange nut : 130 N·m ( 13.0 kg-m, 94.0 lb-ft)
3) Caulk flange nut (1).
CAUTION:
Be sure to caulk flange nut on the output front shaft groove securely as shown in the figure.
If not, it may cause for loosening flange nut.
“a”: 3.8 mm (0.15 in.) or more
4) Apply transfer gear oil to needle roller bearing (1) and synchronizer ring (2), and then install them to output front shaft.
5) Join output rear shaft assembly (3), shift fork shaft assembly (1) and reduction clutch sleeve (2) all together, and then install them to front case.
NOTE:
Be sure to install clutch sleeve (2) to proper direction as shown in the figure.
6) Apply grease to new O-ring (4), and then install it to output rear shaft (3).
“A” : Grease 99000–25010 ( SUZUKI Super Grease A )
7) Install counter gear assembly (1) to front case (2).
8) Apply transfer gear oil to thrust bearing (1) and needle roller bearing (2), and then install them to output rear shaft (3).
NOTE:
Be sure to install thrust bearing (1) to proper direction as shown in the figure.
9) Install input shaft (1), sprocket output gear (2) and drive chain (3) as an assembly to front case.
10) Install steel ball (1) to output rear shaft (2), and then install VSS rotor (3) to output shaft aligning its slot (4) with steel ball.
NOTE:
Turn VSS rotor, and check to rotate together with output rear shaft.
11) After cleaning mating surfaces of both cases, coat mating surface of front case with sealant evenly and put it over rear case.
“A” : Sealant 99000–31260 ( SUZUKI Bond No.1217G )
Sealant amount
Diameter “a”: 1.2 mm (0.05 in.)
12) Align front case and rear case, then install rear flange, tighten new flange nut (1) with flange locked by special tool.
Special Tool
(A) : 09930–40113
Tightening torque
Flange nut ( a ): 130 N·m ( 13.0 kg-m, 94.0 lb-ft)
13) Caulk flange nut (1).
CAUTION:
Be sure to caulk flange nut on the output rear shaft groove securely as shown in the figure.
If not, it may cause for loosening flange nut.
“a”: 3.8 mm (0.15 in.) or more
14) Tighten 11 case bolts.
Tightening torque
Transfer case bolt ( a ): 18 N·m ( 1.8 kg-m, 13.0 lb-ft)
1. Long bolt
2. Short bolt
15) Push in shift fork shaft No.2 (1) in the direction of A to be set at 4H shift position.
2. Shift fork shaft No.1
16) Insert special tool into hole (1) to fix shaft.
Special Tool
(A) : 09922–89810
NOTE:
Move shift shaft No.1 pushing special tool as shown in figure to facilitate installation.
17) Install transfer shift actuator (1) and pinion gear (2), and then clean mating surfaces of both shift actuator and case cover (3), apply sealant to case cover as shown in the figure by such amount that its section is 1.2 mm (0.047 in.) in diameter then mate it with left case and then remove special tool.
“A” : Sealant 99000–31260 ( SUZUKI Bond No.1217G )
NOTE:
Check whether actuator is at 4H position, otherwise set it at 4H position referring to Transfer Shift Actuator Inspection .
Tightening torque
Transfer shift actuator bolt : 20 N·m ( 2.0 kg-m, 14.5 lb-ft)
18) Remove special tool, and then install straight pin (1) and new straight pin plug (2).
Tightening torque
Straight pin plug ( a ): 25 N·m ( 2.5 kg-m, 18.0 lb-ft)
19) Install VSS (1) with new O-ring.
Tightening torque
VSS bolt ( a ): 5 N·m ( 0.5 kg-m, 3.5 lb-ft)
20) Install input front flange, tighten new flange nut (1) with flange locked by special tool.
Special Tool
(A) : 09930–40113
Tightening torque
Flange nut ( a ): 130 N·m ( 13.0 kg-m, 94.0 lb-ft)
21) Caulk flange nut (1).
CAUTION:
Be sure to caulk flange nut on the input shaft groove securely as shown in figure.
If not, it may cause for loosening flange nut.
“a”: 3.8 mm (0.15 in.) or more
22) Install steel ball (2), 4WD switch (1) and 4WD low switch (3).
Tightening torque
4WD switch ( a ): 19 N·m ( 1.9 kg-m, 14.0 lb-ft)
4WD low switch ( b ): 19 N·m ( 1.9 kg-m, 14.0 lb-ft)