Transfer Case Bind-Up (TS 3-02 02096(R))

TRANSFER CASE BIND-UP

TECHNICAL SERVICE BULLETIN

TRANSFER CASE BIND-UP

Model(s): All Suzuki Models

Section: Drivetrain

Bulletin No.: TS 3-02 02096 (R)

Date:

CONDITION

Transfer case bind-up.

CAUSE

Operating the vehicle in 4WD with the automatic or manual locking hubs engaged on dry pavement or on hard surfaced roads.

CORRECTION

Follow the procedure as listed in this bulletin.

REVISION

Transfer case bind-up is a phenomenon that can occur if a 4WD vehicle is driven on dry, hard surfaced roads or on the pavement in 4WD with the front hubs locked (automatic locking hubs will lock automatically when shifted into 4WD and stay locked until the transfer case is shifted back into 2WD and the vehicle is driven in reverse for 4-5 feet). The vehicle begins to slow as if the brakes are being applied and the transfer case lever may bind. The condition is caused by the front and rear wheels turning at different speeds because of unequal tire pressures or turning. The transfer case inner gear components absorb the unequal rate of wheel rotation and begin to bind.

Should the vehicle continue to be driven in this condition, the transfer case gear shift lever will become stuck, the vehicle may become immobile and serious transfer case damage may occur.

To relieve this situation, place the transmission into neutral, and jack up each end of the vehicle, one at a time, and allow the wheels to spin freely. Be sure to chock the wheels that are not raised to secure the vehicle from rolling in either direction. It may be necessary to rock the wheels back and forth when they are raised to unload the bound mechanisms in the transfer case. This procedure will allow all driveline pressures to be relieved and the vehicle can now be operated normally.