LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2004 >> Aerio SX, AWD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Repair Instructions >> Transfer Dismounting and Remounting >> Dismounting
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Transfer Dismounting and Remounting: Dismounting

  1. Disconnect negative cable at battery.
  2. Remove transfer breather hose from clamp on intake manifold.
  3. Remove exhaust cover and exhaust No.1 pipe nuts.
  4. Disconnect HO2S coupler.
  5. Support engine using engine hanger.
  6. Hoist vehicle and remove front wheels.
  7. Drain transfer oil and automatic transaxle fluid.
  8. Remove ball stud bolts (both RH and LH) by removing ball stud lock nuts (1).
  9. Disconnect ball studs of front suspension arms (2) (both RH and LH) from steering knuckles (3).
  10. Remove stabilizer joint.
  11. Remove engine rear mounting nuts (4).
  12. Remove exhaust No.2 pipe hanger bush from suspension frame (5).
  13. Remove engine front mounting nuts (12) and mounting member to body bolts (13).
  14. Support suspension frame (5) by transmission jack or the like to prevent suspension frame from drop down.
  15. Remove 6 suspension frame bolts (6) (both RH and LH).
  16. Lift down suspension frame with suspension arms and stabilizer.
  17. Separate propeller shaft front end from transfer output flange.
  18. Remove exhaust No.1 pipe stay (14).
  19. Remove exhaust No.1 pipe (8).
  20. Remove exhaust No.2 pipe (10).
    Fig 1: Dismounting Transfer Assembly
    G00784099Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove right side drive shaft. See REMOVAL & INSTALLATION .
  22. Remove transfer to transaxle stiffener (1) by removing its 4 bolts (2).
    Fig 2: Removing Transaxle Stiffener
    G00784100Courtesy of SUZUKI OF AMERICA CORP.
  23. Remove transfer to engine stiffener (1) by removing its 6 bolts.
    Fig 3: Remove Engine Stiffener
    G00784101Courtesy of SUZUKI OF AMERICA CORP.
  24. Support transfer assembly with transmission jack.
  25. Remove transfer mounting bolts (1).
    Fig 4: Removing Transfer Mounting Bolts
    G00784102Courtesy of SUZUKI OF AMERICA CORP.
  26. Separate transfer assembly (1) from transaxle (2).
    Fig 5: Separating Transfer Assembly From Transaxle
    G00784103Courtesy of SUZUKI OF AMERICA CORP.
  27. Remove mounting (1) and breather hose (2) from transfer assembly.
    Fig 6: Removing Mounting & Breather Hose From Transfer Assembly
    G00784104Courtesy of SUZUKI OF AMERICA CORP.
scientia non olet · About LEMON Manuals