Extension Case Disassembly and Assembly
Extension Case Disassembly and AssemblyDisassembly
1) Remove rear extension case and damper from front extension case.
2) Disassemble rear extension case (2) as follows, if necessary.
a) Remove oil seal (3) from rear extension case using flat end rod or the like.
b) Remove needle bearing (1) using tools.
Special Tool
(A): 09913-76010
(B): 09944-66020
3) Remove Intermediate shaft from front extension case.
4) Remove oil seal from front extension case using flat end rod or the like, if necessary.
5) Remove intermediate front bearing and/or intermediate rear bearing using hydraulic press (1) and bearing puller (2), if necessary.
Reassembly
1) Install intermediate front bearing (1) and/or intermediate rear bearing (2) using hydraulic press (3) and bearing puller (4).
2) Install oil seal (1) to front extension case (2) until it becomes flush with case using special tool, and then apply grease to oil seal lip.
Note
When installing oil seal, face its spring side inward.
"A": Grease 99000-25011 (SUZUKI Super Grease A)
Special Tool
(A): 09951-46010
3) Install intermediate shaft with bearings to front extension case.
4) Assemble rear extension case (2) as follows.
a) Install needle bearing (1) to rear extension case until it becomes flush with case using special tool.
Special Tool
(A): 09913-75520
b) Install oil seal (1) to rear extension case (2) until it becomes flush with case using special tool, and then apply grease to oil seal lip.
"A": Grease 99000-25011 (SUZUKI Super Grease A)
Special Tool
(A): 09913-75510
5) Clean mating surfaces of front extension case as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate rear extension case with front extension case, and then tighten bolts to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)
Tightening Torque
Extension case bolt: 23 NM (2.3 kg-m, 17.0 lbf-ft)
6) Install damper (1) to rear extension case (2) and tighten damper bolts (3) to specified torque.
Tightening torque
Damper bolts (a): 50 Nm (5.0 kg-m, 35.5 lbf-ft)
