Transfer Disassembly

Reference: TRANSFER ASSEMBLY DISMOUNTING AND REMOUNTING 

Reference: TRANSFER INSPECTION 

Reference: TRANSFER CASE COMPONENT 

Reference: TRANSFER SHIFT ACTUATOR AND SHIFT SHAFT COMPONENT 

Reference: TRANSFER GEAR COMPONENTS 

1. Remove transfer shift actuator (1) and gasket.
   Fig 1: Identifying Transfer Shift Actuator

   Courtesy of SUZUKI OF AMERICA CORP.
2. Remove transfer shift actuator bracket (1).
   Fig 2: Identifying Transfer Shift Actuator Bracket

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3. Remove 4WD switch (1), 4WD low switch (2) and transfer fork switch (3), and then take out shift fork switch steel ball.
   Fig 3: Identifying 4WD Switch, 4WD Low Switch And Transfer Fork Switch

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4. Remove vehicle speed sensor referring to VEHICLE SPEED SENSOR (VSS) REMOVAL AND INSTALLATION .
5. Drive spring pin out of reduction shift yoke by hammering special tool.
   NOTE:

   • Pin may drop into case when driven out. If so take it out when case is disassembled.
   • After spring pin is removed, yoke may be taken out.

   Special Tool 

   (A): 09922-85811 

   Fig 4: Driving Spring Pin Out Of Reduction Shift Yoke By Hammering Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
6. 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: Identifying Center Case, Rear Case & Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
7. Drive out spring pin (1) from front drive shaft yoke (2) using special tool and hammer.
   NOTE: If pin (1) has dropped out into case, take it out when case is disassembled.

   Special Tool 

   (A): 09922-85811 

   Fig 6: Driving Out Spring Pin From Front Drive Shaft Yoke Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
8. Remove rear case from center case.
9. Remove circlip (1) from output rear shaft (2) by using 2 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 7: Identifying Circlip, Output Rear Shaft & Drive Gear

   Courtesy of SUZUKI OF AMERICA CORP.
10. Remove circlip for bearing and pull out output rear shaft No. 2 bearing (1) by combination of special tools.

    Special Tool 

    (C): 09921-57810 

    (D): 09927-18411 

    Fig 8: Identifying Output Rear Shaft No. 2 Bearing & Special Tools

    Courtesy of SUZUKI OF AMERICA CORP.
11. Remove synchronizer plate screws (2) and pull out sprocket bush (4) and needle bearing (3) from output rear shaft (5).
12. Remove drive sprocket (6) with drive chain (7) and synchronizer plate (1).
    Fig 9: Identifying Drive Sprocket, Drive Chain, Synchronizer Plate, Screws, Sprocket Bush, Needle Bearing & Output Rear Shaft

    Courtesy of SUZUKI OF AMERICA CORP.
13. Remove counter shaft plate bolt (1) from front case (3), and counter shaft plate will come off.
14. Remove front case (3) by removing its 9 bolts (2).
    Fig 10: Identifying Counter Shaft Plate Bolt, Front Case & Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
15. Remove input gear needle bearing (1).
16. 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 11: Identifying Input Gear Needle Bearing, Counter Gear Shaft, Counter Gear, Washers And Steel Balls

      Courtesy of SUZUKI OF AMERICA CORP.
17. 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 12: Identifying Counter Gear Shaft, Friction Ring & Rod

    Courtesy of SUZUKI OF AMERICA CORP.
18. Remove locating spring bolt (1) with washer (2) (if equipped), spring (3) and ball (4) for reduction shift.
19. 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.
20. Remove rubber plug (5), and then remove interlock steel ball (9) from rubber plug hole.
    Fig 13: Identifying Spring Bolt, Washer, Spring, Ball, Reduction Shift, Fork, Sleeve, Rubber Plug & Steel Ball

    Courtesy of SUZUKI OF AMERICA CORP.
21. Remove locating spring bolt (1) with washer (2) (if equipped), spring (3) and ball (4) for front drive shift.
22. Pull out front drive shift fork (6) and shaft (5), sleeve (7) and hub (8) all together.
    Fig 14: Identifying Spring Bolt, Washer, Spring, Ball, Front Drive Shift Fork, Sleeve, Hub And Shaft

    Courtesy of SUZUKI OF AMERICA CORP.
23. 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 15: Driving Out Output Rear Shaft Assembly Using Plastic Hammer

    Courtesy of SUZUKI OF AMERICA CORP.
24. 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 16: Identifying Reduction Clutch Hub & Puller

    Courtesy of SUZUKI OF AMERICA CORP.
25. Using puller (3) and hydraulic press, remove output rear shaft No. 1 bearing (2) from shaft (1).
    Fig 17: Identifying Output Rear Shaft No. 1 Bearing, Shaft & Puller

    Courtesy of SUZUKI OF AMERICA CORP.
26. Remove oil seal from center case (1).
27. 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 18: Identifying Output Front Shaft & Center Case

    Courtesy of SUZUKI OF AMERICA CORP.
28. 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 19: Identifying Bearings, Puller & Special Tool

    Courtesy of SUZUKI OF AMERICA CORP.
29. 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 20: Identifying Needle Bearing & Center Case

    Courtesy of SUZUKI OF AMERICA CORP.
30. 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 21: Identifying Rear Case & Needle Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
31. Using special tool, remove circlip (3) of input gear (1) from front case (2).

    Special Tool 

    (H): 09900-06108 

    Fig 22: Identifying Circlip, Input Gear & Front Case

    Courtesy of SUZUKI OF AMERICA CORP.
32. 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 23: Identifying Input Gear & Front Case

      Courtesy of SUZUKI OF AMERICA CORP.
33. Remove circlip (2) of input gear (1) by using special tool.

    Special Tool 

    (I): 09900-06107 

    Fig 24: Identifying Circlip & Input Gear

    Courtesy of SUZUKI OF AMERICA CORP.
34. 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 25: Identifying Bearing, Input Gear & Puller

    Courtesy of SUZUKI OF AMERICA CORP.
35. With spring (3) on front drive fork shaft (4) compressed, remove E-ring (1) and then remove fork (2) and spring (3).
    Fig 26: Identifying Spring, Front Drive Fork Shaft, E-Ring, Fork & Spring

    Courtesy of SUZUKI OF AMERICA CORP.
36. Remove center case gutter (1) from center case (2) using wrench.
    Fig 27: Identifying Center Case Gutter And Center Case

    Courtesy of SUZUKI OF AMERICA CORP.