Disassembly and Reassembly

Transfer Assembly Disassembly and Reassembly

Transfer Dismounting and Remounting

Transfer Assembly Components

Disassembly

NOTE:

It is possible to disassemble transfer assembly without removing intermediate shaft with Step 1) to 4) performed if not necessary.

1) Remove right case oil seal No.1 (1) from transfer right case using special tool.
Special Tool
09913-50121

2) Remove snap ring (2) by using snap ring pliers.
3) Remove intermediate shaft (4) with intermediate shaft bearing (3) from transfer assembly.
4) Remove intermediate shaft bearing (3) from intermediate shaft (4) by using bearing puller and hydraulic press.





5) Remove transfer output retainer assembly (1) and shim (3) by removing retainer bolts (2).
6) Remove transfer case bolts (4).
7) Separate transfer right case (5) from transfer left case (6) by using special tool.
Special Tool

(A): 09912-34510

8) Remove reduction drive gear assembly (7) and reduction driven gear assembly (9).
9) Remove shim (10) and bearing outer races (8).

NOTE:
When it is difficult to remove bearing outer races from cases, remove them with special tool.

Special Tool

(B): 09944-96011









Reassembly

1) Select appropriate shim as follows.
a) Measure distance "a" between taper roller bearing outer races of reduction driven gear assembly (1).
b) Measure depth "b" of left case (2) and "c" of right case (3).
c) Obtain adjusting shim thickness by the following equation.









d) Select a shim which is close to half thickness of the calculated value (necessary shim thickness) from among the available shims to install it between bearing and case at each of right and left sides.
For example:
Measure distance "a" is 110.75 mm (4.360 in.).
Measure depth "b" is 85.8 mm (3.378 in.).
Measure depth "c" is 26.55 mm (1.045 in.).
Necessary shim thickness = 85.8 mm (3.378 in.) + 26.55 mm (1.045 in.) - 110.75 mm (4.360 in.) + 0.1 mm (0.004 in.) = 1.7 mm (0.067 in.)
1.7 mm (0.067 in.) ÷ 2 = 0.85 mm (0.033 in.)
Calculated thickness of new shim = 0.85 mm (0.033 in.)

Available reduction driven gear shim thickness
0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1.00 and 1.05 mm (0.024, 0.026, 0.028, 0.030, 0.031, 0.033, 0.035, 0.037, 0.039 and 0.041 in.)

2) Clean mating surface of right and left cases, and apply sealant to right case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter.

"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)





3) Assemble the following parts in right and left cases by reversing disassembling procedure.
- Reduction drive gear assembly (1)
- Reduction driven gear assembly (3)
- Bearing outer races (2)
- Reduction driven gear shims (5)
- Dowel pin (6)
4) Tighten transfer case bolts (4) to specified torque.

Tightening torque
Transfer case bolt (a): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)





5) Select bevel pinion shim (3) referring to step 1) of "Reassembly" under Transfer Output Retainer Assembly Disassembly and Reassembly Transfer Output Retainer Assembly Disassembly and Reassembly.
6) Inspect tooth contact according to Bevel Gear Tooth Contact Inspection Bevel Gear Tooth Contact Inspection.
7) Install transfer output retainer assembly (2) with bevel pinion shim (3) to transfer left case (4) by tightening retainer bolt (1) to specified torque.

Tightening torque
Transfer output retainer bolt (a): 55 Nm (5.5 kgf-m, 40.0 lbf-ft)





8) Install bolt to bolt hole of flange (2), set dial gauge measuring tip at right angles to bolt (1) as shown in figure. Holding reduction driven gear by hand, take measurement backlash of pinion and bevel gear.

NOTE:
If backlash exceeds specification given below, adjust it by changing thickness ratio of shims assembled in right and left cases in Step 3).

Special Tool

(A): 09900-20607

(B): 09900-20701

Bevel pinion & bevel gear backlash
: 0.1 - 0.2 mm (0.0039 - 0.0078 in.)





9) Install intermediate shaft bearing (1) to intermediate shaft (2) by using special tool.
Special Tool

(A): 09913-84510





10) Install intermediate shaft (2) with bearing (3) in transfer.
11) Install new snap ring (1) to transfer right case by using snap ring pliers.





12) Apply grease to new right case oil seal No.1 lip.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)

13) Drive right case oil seal No.1 (1) in transfer right case (2) by using special tool and hammer.
Special Tool

(A): 09925-16010

Intermediate output oil seal installing depth
"a": 1.5 - 2.0 mm (0.059 - 0.078 in.)