Transfer Dismounting and Remounting: Remounting

Reverse dismounting procedure for remounting of transfer, noting the following points.

CAUTION: The threads of the suspension arm mounting bolts and front suspension frame mounting bolts are coated with friction stabilizer. As the friction stabilizer is lost once the bolts are loosened, reusing the bolts may result in generation of noise or damage to the suspension arms and front suspension frame. Never reuse the suspension arm mounting bolts or front suspension frame mounting bolts that have been loosened. Be sure to replace the bolts with new ones.

Use new O-ring, drive shaft nut and new cotter pin.
Apply grease to left case and O-ring (1) as shown in figure.
"A": Grease 99000-25011 (SUZUKI Super Grease A)

Fig 1: Identifying Left Case Grease Application Areas
Courtesy of SUZUKI OF AMERICA CORP.
Tighten transfer bolts and transfer nut to specified torque.
Tightening torque

Transfer bolt (a): 88 N.m (9.0 kg-m, 65.0 lbf-ft)

Transfer nut (b): 88 N.m (9.0 kg-m, 65.0 lbf-ft)
Tighten transfer stiffener bolts to specified torque in numerical order ("1" - "4") evenly and gradually.
Tightening torque

Transfer stiffener bolt* (c): 55 N.m (5.6 kg-m, 40.5 lbf-ft)

Fig 2: Identifying Transfer Stiffener Bolts Tightening Order
Courtesy of SUZUKI OF AMERICA CORP.

Fig 3: Identifying Transfer Bolt And Nut
Courtesy of SUZUKI OF AMERICA CORP.
Tighten the following bolts and nuts to specified torque.
- Engine rear mounting nut see ENGINE MOUNTINGS COMPONENTS :
- Front suspension frame mounting bolt see TIGHTENING TORQUE SPECIFICATIONS :
- Mounting member nut see ENGINE MOUNTINGS COMPONENTS :
- Suspension arm bolt see TIGHTENING TORQUE SPECIFICATIONS :
- Stabilizer joint nut see TIGHTENING TORQUE SPECIFICATIONS :
- Suspension arm ball joint bolt see TIGHTENING TORQUE SPECIFICATIONS :
- Tie-rod end nut
  - Hydraulic P/S model see TIGHTENING TORQUE SPECIFICATIONS :
  - EPS model see TIGHTENING TORQUE SPECIFICATIONS :
- Front wheel speed sensor bolt
  - ABS model see TIGHTENING TORQUE SPECIFICATIONS :
  - ESP® model see TIGHTENING TORQUE SPECIFICATIONS :
- Propeller shaft bolt see TIGHTENING TORQUE SPECIFICATIONS :
- Center support nut see TIGHTENING TORQUE SPECIFICATIONS :
- Exhaust pipe bolt see EXHAUST SYSTEM COMPONENTS :
- Exhaust pipe clamp bolt see EXHAUST SYSTEM COMPONENTS :
- Exhaust No. 1 pipe stiffener bolt see EXHAUST SYSTEM COMPONENTS :
- Wheel nut see TIGHTENING TORQUE SPECIFICATIONS :
Refill the following oils and fluids.
- Manual transaxle oil (M/T model) see MANUAL TRANSAXLE OIL CHANGE :
- CVT fluid (CVT model) CVT FLUID CHANGE :
- Transfer oil see Transfer Oil Change :
For hydraulic P/S model, refill P/S fluid and bleed air.
- Refill P/S fluid see P/S FLUID CHANGE :
- Bleed air see P/S SYSTEM AIR BLEEDING PROCEDURE :
Verify that there is no oil leakage, fluid leakage and exhaust gas leakage at each connection.
Confirm front wheel alignment.