Transfer Disassembly

Remove 4WD switch (3) and take out steel ball.
Remove 5 bolts and then remove transfer rear cover (1) (if equipped), transfer damper bracket (2) and gear shift lever case (4).

Fig 1: Removing 4WD Switch Transfer Rear Cover (If Equipped)
Courtesy of SUZUKI OF AMERICA CORP.
For transfer for A/T, after removing bolt of select return system, take out spring (4), steel ball (5) and pin (6).

Fig 2: Removing Select Return Spring Bolt & Parts (A/T)
Courtesy of SUZUKI OF AMERICA CORP.
For transfer for manual transmission, remove select return spring bolt (1) and then return spring (2).

Fig 3: Removing Select Return Spring Bolt & Parts (M/T)
Courtesy of SUZUKI OF AMERICA CORP.
Drive spring pin out of reduction shift yoke by hammering special tool.
NOTE:
- Pin may drop into case when driven out. Therefore, take it out when case is disassembled.
- After spring pin is removed, yoke may be taken out.
Special tool
1. (A): 09922-85811
Fig 4: Removing Spring Pin
Courtesy of SUZUKI OF AMERICA CORP.
Remove 15 rear case bolts, and then separate case by using special tool.
NOTE: To separate center case (1) and rear case (2), use special tool at 4 points in turn and make opening wider evenly.

Special tool
1. (B): 09912-34510
Fig 5: Separating Center Case & Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1) from output rear shaft (2) by using screwdrivers and hammer, then pull out speedometer drive gear (3) and steel ball.
NOTE: Watch out for steel ball which comes off from shaft when speedometer drive gear is pulled out so as not to lose it.

Fig 6: Removing Circlip From Output Rear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip for bearing and pull out output rear shaft No. 2 bearing (1) by combination of special tools.
Special tool
1. (C): 09921-57810
2. (D): 09927-18411
Fig 7: Removing Output Rear Shaft No. 2 Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove synchronizer plate screws (2) and pull out sprocket bush (4) and needle bearing (3) from output rear shaft (5).
Remove drive sprocket (6) with drive chain (7) and synchronizer plate (1).
NOTE: Watch out for steel ball which comes off from shaft when bush is pulled out so as not to lose it.

Fig 8: Removing Synchronizer Plate Screws & Pulling Out Sprocket Bush
Courtesy of SUZUKI OF AMERICA CORP.
Remove counter shaft plate bolt (1) from front case (3), and counter shaft plate will come off.
Remove front case (3) by removing its 9 bolts (2).

Fig 9: Removing Counter Shaft Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove input gear needle bearing (1).
Remove counter gear shaft (3) together with counter gear (2), needle bearings, function ring, washers (4) and steel balls (5) from case.
NOTE:
- Watch out for steel balls (5) which come out from between shaft (3) and washers (front and rear) (4) so as not to lose them.
- Check friction ring lip for damage and wear. Replace if necessary.
- Neither O-ring nor friction ring should be removed unless absolutely necessary. If removed, use new parts for reinstallation. Removed ones should not be reused.
Fig 10: Removing Counter Gear Shaft Together With Counter Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove O-ring from counter gear shaft (2) and then remove friction ring (3) from shaft, using a proper size rod (1) and hydraulic press.

Fig 11: Removing O-Ring & Friction Ring From Counter Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove locating spring bolt (1) with washer (2) (if equipped), spring (3) and ball (4) for reduction shift.
Pull out reduction shift shaft (6) together with fork (7) and sleeve (8).
NOTE: For this removal, be sure to place front drive fork shaft at 4WD position.
Remove rubber plug (5), and then remove interlock steel ball (9) from rubber plug hole.

Fig 12: Removing Rubber Plug & Interlock Steel Ball
Courtesy of SUZUKI OF AMERICA CORP.
Remove locating spring bolt (1) with washer (2) (if equipped), spring (3) and ball (4) for front drive shift.
Pull out front drive shift fork (6) and shaft (5), sleeve (7) and hub (8) all together.

Fig 13: Pulling Out Front Drive Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Using plastic hammer (2), drive out output rear shaft assembly (1) with bearing. Output low gear and reduction clutch hub also come off as they are installed to shaft.

Fig 14: Driving Out Output Rear Shaft Assembly With Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Pull off circlip from output rear shaft and remove reduction clutch hub (1) by using puller (2) and hydraulic press. Then pull out output low gear and needle bearing.

Fig 15: Removing Reduction Clutch Hub
Courtesy of SUZUKI OF AMERICA CORP.
Using puller (3) and hydraulic press, remove output rear shaft No. 1 bearing (2) from shaft (1).

Fig 16: Removing Output Rear Shaft No. 1 Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal from center case (1).
Using plastic hammer, drive out output front shaft (2) together with bearings.
CAUTION: If oil seal remains in center case, be careful not to damage oil seal by hitting. Use drive punch for hammering.

Fig 17: Driving Out Output Front Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Take off bearings (1, 3) from shaft by using hydraulic press and puller (2). Removal of front side bearing requires special tool additionally as shown in the figure.
Special tool
1. (E): 09925-98221
Fig 18: Removing Bearings From Shaft
Courtesy of SUZUKI OF AMERICA CORP.
To remove needle bearing (2) from center case (1), combine special tools as shown in the figure and press them.
Special tool
1. (F): 09913-84510
2. (G): 09941-64511
Fig 19: Removing Needle Bearing From Center Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal from rear case (1). And then, using special tools and hydraulic press, remove needle bearing (2) from rear case.
CAUTION: Be careful not to damage oil seal, if it remains in rear case.

Special tool
- (F): 09913-84510
- (G): 09941-64511
Fig 20: Removing Oil Seal & Needle Bearing From Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool, remove circlip (3) of input gear (1) from front case (2).
Special tool
1. (H): 09900-06108
Fig 21: Removing Circlip Of Input Gear From Front Case
Courtesy of SUZUKI OF AMERICA CORP.
Using plastic hammer, drive input gear (2) out of front case (1).
NOTE:
- Be careful not to damage oil seal (3) by hitting.
- If removed, do not reuse oil seal (3).
Fig 22: Driving Input Gear Out Of Front Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (2) of input gear (1) by using special tool.
Special tool
1. (I): 09900-06107
Fig 23: Removing Circlip Of Input Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove bearing (2) from input gear (1) by using puller (3) and hydraulic press.
NOTE: Use metal pad for this removal, or gear spline may get damaged.

Special tool
1. (J): 09951-76010
Fig 24: Removing Bearing From Input Gear
Courtesy of SUZUKI OF AMERICA CORP.
With spring (3) on front drive fork shaft (4) compressed, remove circlip (1) and then remove fork (2) and spring (3).

Fig 25: Removing Circlip, Fork & Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove center case gutter (1) from center case (2) with using wrench.

Fig 26: Removing Center Case Gutter From Center Case
Courtesy of SUZUKI OF AMERICA CORP.