Transfer Disassembly

Remove 4WD switch (3) and take out steel ball.
Remove 5 bolts and then remove gear shift lever case (4).

Fig 1: Removing Gear Shift Lever Case
Courtesy of SUZUKI OF AMERICA CORP.
For transfer for A/T and manual transmission, after removing bolt of select return system, take out spring (4), steel ball (5) and pin (6).

Fig 2: Removing Bolt Of Select Return System, Spring, Steel Ball And Pin
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
Courtesy of SUZUKI OF AMERICA CORP.
By hammering special tool, drive spring pin out of reduction shift yoke.
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 either taken out.
Special tool

(A): 09922-85811

Fig 4: Removing Drive Spring Pin Of Reduction Shift Yoke
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

(B): 09912-34510

Fig 5: Separating Case By Using Special Tool
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.

Fig 6: Removing Circlip From Output Rear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip for bearing and pull out bearing No.2 (1) by combination of special tools.
Special tool

(C): 09921-57810

(D): 09927-18411

Fig 7: Removing Circlip For 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 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 Sprocket With Drive Chain And Synchronizer Plate
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 Bolt From Front Case, And Counter Shaft Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove input gear needle bearing (1). Remove counter gear shaft (3) together with needle bearings, spacer, 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 Input Gear Needle Bearing
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 From Counter Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove locating spring bolt (1) with washer (2), spring (3) and ball (4) for reduction shift. Remove rubber plug (5) as well.
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.

Fig 12: Removing Spring Bolt With Washer, Spring And Ball For Reduction Shift
Courtesy of SUZUKI OF AMERICA CORP.
Remove locating spring bolt (1) with washer (2), 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.
NOTE: Watch out for interlock steel ball which comes out from between 2 shift shafts so as not to lose it. If it doesn't come out, remove rubber plug and take it out.

Fig 13: Removing Front Drive Shift Fork And Shaft, Sleeve And Hub
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: Removing 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 Circlip From Output Rear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Using puller (3) and hydraulic press, remove bearing No. 1 (2) from shaft (1).

Fig 16: Removing Bearing No. 1 From Shaft
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: Removing Oil Seal From Center Case
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

(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

(F): 09913-84510

(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 same special tools and hydraulic press as in above step, 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 From Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool, remove circlip (3) of input gear (1) from front case (2).
NOTE: Be sure to use right tool to ensure proper work.

Special tool

(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.
Fig 22: Removing Drive Input Gear Of Front Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (2) of input gear (1) by using special tool.
Special tool

(I): 09900-06107

Fig 23: Removing Circlip Of Input Gear By Using Special Tool
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

(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 Fork And 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.