Removal and Replacement
Transfer Dismounting and Remounting
Dismounting
1) Disconnect negative (-) cable at battery.
2) Drain the following oils and fluids.
- Manual transaxle oil (M/T model): Removal and Replacement
- CVT fluid (CVT model): Removal and Replacement
- Transfer oil: Removal and Replacement
- P/S fluid (Hydraulic P/S model): Removal and Replacement
3) Remove right side drive shaft assembly. Front Drive Shaft Assembly Removal and Installation
4) Remove propeller shaft. Propeller Shaft Assembly Removal and Installation
5) Carry out Step 2) to 13) of "Removal" under Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation (2WD Model) Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation (2WD Model).
6) Remove engine rear mounting. [1][2]Diagrams
7) Disconnect breather hose (1).
8) Remove transfer stiffener (2), transfer bolts and transfer nut.
9) Separate transfer (3) from transaxle.
CAUTION:
When you remove the transfer assembly, it could slip out of your hands and drop, causing personal injury or damage to the transfer assembly.
When removing the transfer assembly, be careful not to drop it.
10) Lower front suspension frame with steering gear case and transfer, and then remove transfer.
11) Remove O-ring (1) and dowel pin (2).
Remounting
Reverse dismounting procedure for remounting of transfer, noting the following points.
NOTE:
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)
- Tighten transfer bolts and transfer nut to specified torque.
Tightening torque
Transfer bolt (a): 88 Nm (9.0 kgf-m, 65.0 lbf-ft)
Transfer nut (b): 88 Nm (9.0 kgf-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 Nm (5.6 kgf-m, 40.5 lbf-ft)
- Tighten the following bolts and nuts to specified torque.
- Engine rear mounting nut: [1][2]Diagrams
- Front suspension frame mounting bolt: Front Suspension Frame, Stabilizer Bar and/or Bush Components
- Mounting member nut: [1][2]Diagrams
- Suspension arm bolt: Suspension Arm Removal and Installation
- Stabilizer joint nut: Front Strut Assembly Removal and Installation
- Suspension arm ball joint bolt: Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation
- Tie-rod end nut
- Hydraulic P/S model: Removal and Installation
- EPS model: Removal and Installation
- Front wheel speed sensor bolt
- ABS model: Front Wheel Speed Sensor Removal and Installation
- ESP(R) model: Front Wheel Speed Sensor Removal and Installation
- Propeller shaft bolt: Propeller Shaft Assembly Removal and Installation
- Center support nut: Propeller Shaft Assembly Removal and Installation
- Exhaust pipe bolt: Exhaust System Components
- Exhaust pipe clamp bolt: Exhaust System Components
- Exhaust No.1 pipe stiffener bolt: Exhaust System Components
- Wheel nut: Removal and Replacement
- Refill the following oils and fluids.
- Manual transaxle oil (M/T model): Removal and Replacement
- CVT fluid (CVT model): Removal and Replacement
- Transfer oil: Removal and Replacement
- For hydraulic P/S model, refill P/S fluid and bleed air.
- Refill P/S fluid: Removal and Replacement
- Bleed air: Service and Repair
- Verify that there is no oil leakage, fluid leakage and exhaust gas leakage at each connection.
- Confirm front wheel alignment. Front Wheel Alignment Inspection and Adjustment