Transfer Reassembly

Reference: TRANSFER ASSEMBLY DISMOUNTING AND REMOUNTING 

Reference: TRANSFER DISASSEMBLY 

Reference: TRANSFER INSPECTION 

Reference: TRANSFER CASE COMPONENT 

Reference: TRANSFER SHIFT ACTUATOR AND SHIFT SHAFT COMPONENT 

Reference: TRANSFER GEAR COMPONENTS 

1. Using hydraulic press and special tool, press-fit needle bearing into center case (1). As shown in figure, apply straightedge (2) to top surface of case and press-fit till limit line (3) of special tool aligns with bottom surface of straightedge (2) (i.e., case surface).
   NOTE:

   • Press-fitting needle bearing according to above procedure will set needle bearing 3 mm (0.12 in.) before it hits case bottom.
   • Once it is press-fitted all way down to case bottom, removal would be very difficult even if it becomes necessary.

   Special Tool 

   (A): 09951-76010 

   Fig 1: Identifying Center Case, Straightedge & Limit Line

   Courtesy of SUZUKI OF AMERICA CORP.
2. Using special tool and hammer, drive oil seal (1) into center case (2) until it becomes flush with case surface. Apply grease "A" to oil seal lip.

   "A": Grease 99000-25010 

   Special Tool 

   (B): 09913-75520 

   Fig 2: Driving Oil Seal Into Center Case

   Courtesy of SUZUKI OF AMERICA CORP.
3. Install oil gutter to center case (2) and tighten bolt (1) applying thread lock cement "B".

   Tightening torque 

   Center case gutter bolt a: 8 N.m (0.8 kg-m, 6.0 lb-ft) 

   "B": Thread lock cement 99000-32020 

   Fig 3: Identifying Center Case And Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
4. Using special tool and hydraulic press, install needle bearing (4) into rear case (1). As shown in the figure, apply straightedge (2) to case surface and press-fit needle bearing up to clearance "a" between top (3) of special tool (A) and bottom surface of straightedge (2).
   NOTE: As with needle bearing in center case, above installation procedure will set needle bearing at a position 3 mm (0.12 in.) before it hits case bottom.

   Special Tool 

   (A): 09913-70123 

   Fig 4: Identifying Needle Bearing, Rear Case, Straightedge, Top & Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
5. Using special tool and hammer, install oil seal (1) into rear case (2) until it becomes flush with case surface. Apply grease "A" to oil seal lip.

   "A": Grease 99000-25010 

   Special Tool 

   (B): 09913-75520 

   Fig 5: Installing Oil Seal Into Rear Case

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install rear case plate (1) and bolt (2) applying thread lock cement "B".
   NOTE: Removal of rear case plate is not required normally. However, if it is removed or replaced, install it with bolt applied with thread lock cement.

   "B": Thread lock cement 99000-32020 

   Tightening torque 

   Rear case plate bolt a: 8 N.m (0.8 kg-m, 6.0 lb-ft) 

   Fig 6: Identifying Rear Case Plate And Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
7. Using hydraulic press and special tools, install bearings (2) to front shaft (1). Bearings for both front and rear are identical.

   Special Tool 

   (C): 09913-84510 

   Fig 7: Installing Bearings & Front Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
8. Using hydraulic press, drive output front shaft assembly (2) into center case (1).
   Fig 8: Identifying Output Front Shaft Assembly & Center Case

   Courtesy of SUZUKI OF AMERICA CORP.
9. Using hydraulic press and special tools, install output rear shaft No. 1 bearing (1) into output rear shaft (2). Place circlip portion of bearing on top as shown in figure.

   Special Tool 

   (D): 09925-18011 

   (E): 09940-53111 

   Fig 9: Identifying Output Rear Shaft No. 1 Bearing & Output Rear Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
10. Install needle bearing (3) and output low gear (4) and then press-fit reduction clutch hub (5) onto output rear shaft (1) by using hydraulic press and special tools, and then secure them with circlip (6). Hub has specific installing direction.

    Special Tool 

    (D): 09925-18011 

    (E): 09940-53111 

    Fig 10: Identifying Needle Bearing, Output Low Gear, Output Rear Shaft, Circlip, Output Rear Shaft No. 1 Bearing & Puller

    Courtesy of SUZUKI OF AMERICA CORP.
11. Combine special tools and press-fit output rear shaft assembly into center case (1).
    NOTE: Use special tool (F) with its under-cut side faced down (toward bearing).

    Special Tool 

    (D): 09940-51710 

    (E): 09940-53111 

    (F): 09951-26010 

    Fig 11: Identifying Center Case & Special Tools

    Courtesy of SUZUKI OF AMERICA CORP.
12. Install front drive shift fork (3) to front drive shift shaft (5).
    Fig 12: Identifying Front Drive Shift Fork, Front Drive Shift Shaft, Circlip, Washer & Spring

    Courtesy of SUZUKI OF AMERICA CORP.
13. Fit sleeve to front drive clutch hub (1), synchronizer spring (6) with synchronizer outer ring (3), center cone (4) and synchronizer inner ring (5). When installing, note that front drive clutch hub (1) and sleeve (2) have specific installing direction.
    Fig 13: Identifying Front Drive Clutch Hub, Synchronizer Spring, Sleeve, Synchronizer Outer Ring, Center Cone And Synchronizer Inner Ring

    Courtesy of SUZUKI OF AMERICA CORP.
14. Install front drive fork shaft assembly (5) and sleeve (7) and hub (8) together into center case all at once. Then put locating ball (4) and spring (3) also into case and tighten locating spring bolt (1) with washer (2) (if equipped) to specified torque.

    "A": Thread lock cement 99000-32020 

    Tightening torque 

    Locating spring bolt a: 26 N.m (2.6 kg-m, 19.0 lb-ft) 

    Fig 14: Identifying Front Drive Fork Shaft Assembly, Sleeve, Hub, Ball, Spring, Bolt, Washer, Shift Fork & Output Rear Shaft

    Courtesy of SUZUKI OF AMERICA CORP.
15. With the outer ring (5), spring (4) (if equipped), cone (6) and the inner ring (7) put together and installed to sprocket gear (2) as shown in the figure, install them together with chain (3) to output rear shaft (1).
    Fig 15: Identifying Outer Ring, Spring, Cone, Inner Ring, Sprocket Gear, Output Rear Shaft And Chain

    Courtesy of SUZUKI OF AMERICA CORP.
16. Install needle bearing (3) to sprocket gear (2).
17. Install bush (4) to sprocket gear (2).
    Fig 16: Identifying Needle Bearing, Sprocket Gear & Bush

    Courtesy of SUZUKI OF AMERICA CORP.
18. Install synchronizer plate (1).

    Tightening torque 

    Synchronizer plate screw a: 8 N.m (0.8 kg-m, 6.0 lb-ft) 

    "B": Thread lock cement 99000-32020 

    Fig 17: Identifying Synchronizer Plate

    Courtesy of SUZUKI OF AMERICA CORP.
19. Using special tool, press-fit output rear shaft No. 2 bearing (1) into output rear shaft. It is necessary to place support base at lower end of shaft.

    Special Tool 

    (D): 09940-51710 

    (G): 09926-68310 

    Fig 18: Press-Fitting Output Rear Shaft No. 2 Bearing Into Output Rear Shaft Using Special Tools

    Courtesy of SUZUKI OF AMERICA CORP.
20. After installing circlip (4) and steel ball (5), install speedometer drive gear (3) and secure it with circlip (2).
    Fig 19: Identifying Circlips, Steel Ball, Output Rear Shaft And Speedometer Drive Gear

    Courtesy of SUZUKI OF AMERICA CORP.
21. Install interlock steel ball (1).
    Fig 20: Identifying Interlock Steel Ball, Front Drive Shift Shaft & Center Case

    Courtesy of SUZUKI OF AMERICA CORP.
22. Combine sleeve (8) to reduction shift shaft assembly (6) and install them into center case (9). Then put locating ball (4) and spring (3) also into case and tighten locating spring bolt (1) with washer (2) (if equipped).
    NOTE:

    • Circumferential groove mark (thicker rail side which works as shift stopper) should be inside (rear).
    • Hub has no specific direction.

    "A": Thread lock cement 99000-32020 

    Tightening torque 

    Locating spring bolt a: 26 N.m (2.6 kg-m, 19.0 lb-ft) 

23. With sealant applied to rubber plug (5), insert it into hole in case.
    NOTE: When installing reduction shift shaft, front drive shift shaft must be placed at 4WD position.

    "C": Sealant 99000-31110 

    Fig 21: Identifying Rubber Plug, Shift Lock, Groove, Sleeve, Reduction Shift Shaft Assembly, Center Case, Locating Ball, Spring, Bolt & Washer

    Courtesy of SUZUKI OF AMERICA CORP.
24. If friction ring (2) has been removed from counter shaft (1), press-fit new one onto shaft, using care so that it is installed in proper direction and position as shown in the figure.

    Special Tool 

    (K): 09913-80113 

    New friction ring installing position 

    "a": 39.5 mm (1.56 in.) 

    Fig 22: Identifying Friction Ring & Counter Shaft

    Courtesy of SUZUKI OF AMERICA CORP.
25. Install needle bearings (3), spacer (4), counter gear (2), steel balls (5) and washers (1) onto shaft (6).
    NOTE: Washers must be installed with its oil slot side facing gear.
    Fig 23: Identifying Needle Bearings, Spacer, Counter Gear, Steel Balls, Washers And Shaft

    Courtesy of SUZUKI OF AMERICA CORP.
26. Install counter shaft assembly into case. If O-ring (5) has been removed, install new O-ring onto shaft (3) and apply grease "A".

    Also, install low gear needle bearing (1).

    "A": Grease 99000-25010 

    Fig 24: Identifying O-Ring, Washer, Low Gear Needle Bearing, Shaft, Counter Gear & Washer

    Courtesy of SUZUKI OF AMERICA CORP.
27. With circlip (2) placed on input gear (1), press-fit input gear bearing (3).
28. Fix bearing with circlip (4).

    Special Tool 

    (D): 09925-18011 

    (E): 09940-53111 

    (H): 09900-06107 

    Fig 25: Identifying Circlips, Input Gear, Bearing & Special Tools

    Courtesy of SUZUKI OF AMERICA CORP.
29. Install oil seal (1) to front case (2) so that end surface of oil seal becomes flush with that case. Apply grease "A" to oil seal lip.

    "A": Grease 99000-25010 

    Special Tool 

    (B): 09913-75520 

    Fig 26: Installing Oil Seal To Front Case

    Courtesy of SUZUKI OF AMERICA CORP.
30. Using special tool, drive input gear assembly (2) into front case (1).

    Special Tool 

    (I): 09951-16080 

    Fig 27: Driving Input Gear Assembly Into Front Case

    Courtesy of SUZUKI OF AMERICA CORP.
31. Fix with circlip (1) by means of snap ring pliers.

    Special Tool 

    (J): 09900-06108 

    Fig 28: Identifying Circlip & Special Tool

    Courtesy of SUZUKI OF AMERICA CORP.
32. Oil to rotating parts and clean mating surfaces of center case (1) and front case (2).
33. Apply sealant "C" to mating surface of front case (2) evenly and put cases together.
    NOTE:

    • For smooth installation of front case, apply grease to counter shaft O-ring.
    • When mating front case, make sure that input gear meshes with counter gear first.

    "C": Sealant 99000-31110 

    Fig 29: Identifying Center Case & Front Case

    Courtesy of SUZUKI OF AMERICA CORP.
34. Torque 9 front case bolts (2) to specification.

    Tightening torque 

    Front case bolt d: 23 N.m (2.3 kg-m, 17.0 lb-ft) 

35. Torque counter shaft plate fixing bolt (1) applied with thread lock cement to specification.
    NOTE:

    • After tightening bolts, check input gear and output rear shaft for smooth rotation by hand at low and high speed position.
    • Also check front drive shift for proper operation.

    "B": Thread lock cement 99000-32020 

    Tightening torque 

    Countershaft plate bolt c: 23 N.m (2.3 kg-m, 17.0 lb-ft) 

    Fig 30: Identifying Counter Shaft Plate Fixing Bolt, Front Case Bolts & Front Case

    Courtesy of SUZUKI OF AMERICA CORP.
36. Before assembling rear case (2), adjust clearance "c" selecting shim size as follows.
    Fig 31: Identifying Rear Case, Center Case, Rear Shaft No. 1 Bearing & Rear Shaft No. 2 Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
    1. Measure rear case (1) dimension "a" (from mating surface to bearing bore bottom) by using straightedge (2) and vernier caliper. Width of straightedge "d" plus "a" is obtained.
       Fig 32: Identifying Rear Case & Straightedge

       Courtesy of SUZUKI OF AMERICA CORP.
    2. Place straightedge on bearing No. 2 (2) securely and measure bearing height "b" (from center case (1) mating surface to No. 2 bearing top).
       CAUTION: Bridging straightedge between No. 2 bearing and output front shaft bearing brings misreading value.
    3. Obtain clearance "c" using the following calculation.

       "c"= ("a"+"d") - ("b"+"d")

       Fig 33: Identifying Center Case & Bearing No. 2

       Courtesy of SUZUKI OF AMERICA CORP.
    4. Select a shim from among the following available sizes and install it in bearing bore of rear case.
       CAUTION: Installing of over sized shim beyond specification in the following table may cause tight rotation of rear shaft and consequential bearing damage.

       Shim specifications 

       SHIM SPECIFICATIONS
       
       

       Clearance "c"	Shim size
       0 - 0.13 mm (0 - 0.005 in.)	NO NEED
       0.13 - 0.23 mm (0.005 - 0.009 in.)	0.1 mm (0.004 in.)
       0.23 - 0.33 mm (0.009 - 0.013 in.)	0.2 mm (0.008 in.)
       0.33 - 0.43 mm (0.013 - 0.017 in.)	0.3 mm (0.012 in.)
       0.43 - 0.53 mm (0.017 - 0.021 in.)	0.4 mm (0.016 in.)
       0.53 - 0.58 mm (0.021 - 0.023 in.)	0.5 mm (0.020 in.)

37. Clean mating surfaces of both center (2) and rear (1) cases again, apply sealant "C" to mating surface of rear case.

    "C": Sealant 99000-31110 

    Fig 34: Identifying Center Case, Rear Case & Shim

    Courtesy of SUZUKI OF AMERICA CORP.
38. Put together center case (1) and rear case (2) with installing front drive shift yoke (3) and reduction drive shift yoke (4) installed to front drive shift shaft (5) and reduction drive shift shaft (6).
    Fig 35: Identifying Center Case, Rear Case, Front Drive Shift Yoke, Reduction Drive Shift Yoke, Front Drive Shift Shaft & Reduction Drive Shift Shaft

    Courtesy of SUZUKI OF AMERICA CORP.
39. Torque 15 rear case bolts (2) to specification.
    NOTE: After tightening bolts, provisionally install universal joint flange into rear shaft and check to make sure smooth rotation of shaft.

    Tightening torque 

    Rear case bolt e: 23 N.m (2.3 kg-m, 17.0 lb-ft) 

    Fig 36: Identifying Rear Case Bolts & Clamp

    Courtesy of SUZUKI OF AMERICA CORP.
40. Fir reduction drive shift yoke (1) to reduction drive shift shaft (2) and front drive shift yoke (3) to front drive shift shaft (4) and fix it with spring pin (5).
    NOTE: Be careful not to let spring pin fall off.
    Fig 37: Identifying Drive Shift Yoke, Reduction Drive Shift Shaft, Front Drive Shift Yoke, Front Drive Shift Shaft And Spring Pin

    Courtesy of SUZUKI OF AMERICA CORP.
41. Install steel balls, and then install 4WD switch (1), 4WD low and shift fork switch (3).

    Tightening torque 

    4WD switch a: 20 N.m (2.0 kg-m, 14.5 lb-ft) 

    4WD low switch b: 20 N.m (2.0 kg-m, 14.5 lb-ft) 

    Shift fork switch c: 20 N.m (2.0 kg-m, 14.5 lb-ft) 

    Fig 38: Identifying 4WD Switch And Shift Fork Switch

    Courtesy of SUZUKI OF AMERICA CORP.
42. Install vehicle speed sensor to rear case.
43. Fix lead of 4WD switch (1) with clamp.
44. Clean mating surfaces of both transfer shift actuator bracket (1) and rear case (2), and with sealant "C" applied to mating surface of transfer shift actuator bracket (1), push both cases together.

    "C": Sealant 99000-31110 

45. Confirm that front drive shift yoke and reduction drive yoke operate smoothly.
46. Confirm resistance of 4WD switch (1), 4WD low switch (2) and transfer fork switch (3) at each transfer shift position.

    4WD switch specification 

    2H position: Continuity 

    4H position: No continuity 

    N position: No continuity 

    4L position: No continuity 

    4WD low switch specification 

    2H position: No continuity 

    4H position: No continuity 

    N position: Continuity 

    4L position: Continuity 

    Transfer fork switch specification 

    2H position: No continuity 

    4H position: Continuity 

    N position: No continuity 

    4L position: Continuity 

    Fig 39: Checking 4WD Switch, 4WD Low Switch And Transfer Fork Switch

    Courtesy of SUZUKI OF AMERICA CORP.
47. Install vehicle speed sensor referring to VEHICLE SPEED SENSOR (VSS) REMOVAL AND INSTALLATION .
48. Shift front drive shift yoke (1) and reduction drive yoke (2) to 4H position as shown.
    Fig 40: Identifying Shift Yoke And Reduction Drive Yoke

    Courtesy of SUZUKI OF AMERICA CORP.
49. Install transfer shift actuator bracket (1) to transfer rear case (2), and then tighten transfer shift actuator bracket bolts (3) first and then bolt (4).

    Tightening torque 

    Transfer shift actuator bracket mounting bolt a: 23 N.m (2.3 kgf-m, 17.0 lb-ft) by specified procedure 

    Fig 41: Identifying Transfer Shift Actuator Bracket, Transfer Rear Case And Transfer Shift Actuator Bracket Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
50. Install transfer shift actuator referring to TRANSFER SHIFT ACTUATOR REMOVAL AND INSTALLATION .