Transfer Assembly

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 before it hits case bottom.
- Once it is press-fit all way down to case bottom, removal would be very difficult if it becomes necessary.
Special tool
1. (A): 09951-76010
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
1. (B): 09913-75520
Fig 2: Driving Oil Seal Into Center Case
Courtesy of SUZUKI OF AMERICA CORP.
Install oil gutter to center case (2) and tighten bolt (1) applying thread lock cement "B".
Tightening torque
1. Center case gutter bolt (a): 8 N.m (0.8 kg-m, 6.0 lb-ft)
2. "B": Thread lock cement 99000-32020
Fig 3: Installing Oil Gutter To Center Case
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and hydraulic press, install needle bearing into rear case (1). As shown in the figure. Apply straightedge (2) to case surface and press-fit till top (3) of special tool (A) aligns with bottom surface of straightedge (2) (i.e., case surface).
NOTE: As with needle bearing in center case, above installation procedure will set needle bearing at a position 3 mm before it hits case bottom.

Special tool
1. (A): 09951-76010
  
  Fig 4: Installing Needle Bearing Into Rear Case
  Courtesy of SUZUKI OF AMERICA CORP.
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
1. (B): 09913-75520
Fig 5: Installing Oil Seal Into Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
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.
1. "B": Thread lock cement 99000-32020
Tightening torque
1. Rear case plate bolt (a): 8 N.m (0.8 kg-m, 6.0 lb-ft)
Fig 6: Installing Rear Case Plate & Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Using hydraulic press and special tools, install bearings (2) to front shaft (1). Bearings for both front and rear are identical.
Special tool
1. (C): 09913-84510
Fig 7: Installing Bearings To Front Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Using hydraulic press, drive output front shaft assembly (2) into center case (1).

Fig 8: Driving Output Front Shaft Assembly Into Center Case
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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
1. (D): 09925-18011
2. (E): 09940-53111
Fig 9: Installing Output Rear Shaft No. 1 Bearing Into Output Rear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
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 tool and secure them with circlip (6). Hub has specific installing direction.
Special tool
1. (D): 09925-18011
2. (E): 09940-53111
Fig 10: Installing Needle Bearing & Output Low Gear
Courtesy of SUZUKI OF AMERICA CORP.
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
1. (D): 09925-18011
2. (E): 09940-53111
3. (F): 09951-26010
Fig 11: Press-Fitting Output Rear Shaft Assembly Into Center Case
Courtesy of SUZUKI OF AMERICA CORP.
Install fork to corresponding shift shaft as shown.

Fig 12: Installing Fork To Corresponding Shift Shaft
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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: Fitting Sleeve To Front Drive Clutch Hub
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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
1. Locating spring bolt (a): 26 N.m (2.6 kg-m, 19.0 lb-ft)
Fig 14: Installing Front Drive Fork Shaft Assembly & Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
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: Installing Sprocket Gear & Chain To Output Rear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install steel ball (1) to output rear shaft (6) front side ball hole between output rear shaft No. 2 bearing position and speedometer drive gear position.
Install needle bearing (3) to sprocket gear (2).
Install bush (4) to sprocket gear (2) with aligning sprocket gear ball hole (5) to steel ball (1).

Fig 16: Installing Components To Output Rear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install synchronizer plate (1).
Tightening torque
1. Synchronizer plate screw (a): 10 N.m (1.0 kg-m, 7.5 lb-ft)
2. "B": Thread lock cement 99000-32020
Fig 17: Installing Synchronizer Plate
Courtesy of SUZUKI OF AMERICA CORP.
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
1. (D): 09925-18011
2. (G): 09926-68310
Fig 18: Press-Fitting Output Rear Shaft No. 2 Bearing Into Output Rear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
After installing large size circlip (4) and steel ball (5), install speedometer drive gear (3) and secure it with small size circlip (2).

Fig 19: Installing Speedometer Drive Gear
Courtesy of SUZUKI OF AMERICA CORP.
Install interlock steel ball (1).

Fig 20: Installing Interlock Steel Ball
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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
1. Locating spring bolt (a): 26 N.m (2.6 kg-m, 19.0 lb-ft)
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.
1. "C": Sealant 99000-31110
Fig 21: Installing Components In Center Case
Courtesy of SUZUKI OF AMERICA CORP.
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
1. (K): 09913-80112
New friction ring installing position
1. "a": 39.5 mm (1.56 in.)
Fig 22: Installing Friction Ring On Counter Shaft
Courtesy of SUZUKI OF AMERICA CORP.
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: Installing Needle Bearings
Courtesy of SUZUKI OF AMERICA CORP.
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).
1. "A": Grease 99000-25010
Fig 24: Installing Counter Shaft Assembly Into Case
Courtesy of SUZUKI OF AMERICA CORP.
With circlip (2) placed on input gear (1), press-fit input gear bearing (3).
Fix bearing with circlip (4).
Special tool
1. (D): 09925-18011
2. (E): 09940-53111
3. (H): 09900-06107
Fig 25: Fixing Bearing With Circlip
Courtesy of SUZUKI OF AMERICA CORP.
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
1. (B): 09913-75520
Fig 26: Installing Oil Seal To Front Case
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool, drive input gear assembly (2) into front case (1).
Special tool
1. (I): 09951-16080
Fig 27: Driving Input Gear Assembly Into Front Case
Courtesy of SUZUKI OF AMERICA CORP.
Fix with circlip (1) by means of snap ring pliers.
Special tool
1. (J): 09900-06108
Fig 28: Installing Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Oil to rotating parts and clean mating surfaces of center case (1) and front case (2).
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.
1. "C": Sealant 99000-31110
Fig 29: Mating Center Case & Front
Courtesy of SUZUKI OF AMERICA CORP.
Torque 9 front case bolts (2) to specification.
Tightening torque
1. Front case bolt (d): 23 N.m (2.3 kg-m, 17.0 lb-ft)
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
1. Countershaft plate bolt (c): 23 N.m (2.3 kg-m, 17.0 lb-ft)
Fig 30: Tightening Front Case Bolts & Counter Shaft Plate Fixing Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Before assembling rear case (2), adjust clearance "c" selecting shim size as follows.

Fig 31: Identifying Clearance "c"
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: Measuring Rear Case Dimension "A"
  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.
3. Obtain clearance "C" in the following calculation.
  1. "C" = ("A" + "D") - ("B" + "D")
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.

Fig 33: Shim Specifications Chart
Courtesy of SUZUKI OF AMERICA CORP.

Fig 34: Measuring Bearing Height "B"
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surfaces of both center (2) and rear (1) cases again, apply sealant "C" to mating surface of rear case.
1. "C": Sealant 99000-31110
Fig 35: Cleaning Mating Surfaces Of Both Center & Rear Cases
Courtesy of SUZUKI OF AMERICA CORP.
Put together center case (1) and rear case (2) with installing yoke (3) to reduction shift shaft (4).

Fig 36: Mating Center Case & Rear Case
Courtesy of SUZUKI OF AMERICA CORP.
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
1. Rear case bolt (e): 23 N.m (2.3 kg-m, 17.0 lb-ft)
Fig 37: Tightening Rear Case Bolts
Courtesy of SUZUKI OF AMERICA CORP.
For transfer for manual transmission, perform the following procedure.
1. With reduction shift shaft shifted to high speed side, fit yoke to shaft and install return spring (2) as shown in the figure. Tighten bolt (1) to specified torque.
  Tightening torque
  1. Select return spring bolt (for M/T) (f): 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
2. Fix reduction shift yoke with spring pin (4) while aligning shift yoke with shift shaft as shown in the figure.
  
  Fig 38: Fitting Yoke To Shaft And Installing Return Spring
  Courtesy of SUZUKI OF AMERICA CORP.
For transfer for A/T, perform the following procedure.
1. With reduction shift shaft (1) shifted to left (at high speed side) as shown in figure, fit yoke (2) to shaft (1) and fix it with spring pin.
  NOTE: Be careful not to let spring pin fall off.
2. Torque locating spring bolts (4) of shifters to specification.
  Tightening torque
  1. Locating spring bolt (g): 26 N.m (2.6 kg-m, 19.0 lb-ft)
  Fig 39: Fitting Yoke To Shaft & Fixing It With Spring Pin
  Courtesy of SUZUKI OF AMERICA CORP.
Install steel balls (1) and 4WD/4WD-LOW switches (2).
Tightening torque
1. 4WD switch (h): 20 N.m (2.0 kg-m, 14.5 lb-ft)
2. 4WD-LOW switch: 20 N.m (2.0 kg-m, 14.5 lb-ft)
Fig 40: Installing Steel Balls & 4WD/4WD-Low Switches
Courtesy of SUZUKI OF AMERICA CORP.
Install vehicle speed sensor to rear case.
Fix lead of 4WD switch (1) with clamp.
Apply grease "A" to select return system parts and install them. Then torque select return spring bolt (5) to specification (For transfer with A/T only).
"A": Grease 99000-25010

Tightening torque
1. Select return spring bolt (for A/T) (i): 35 N.m (3.5 kg-m, 25.5 lb-ft)
Clean mating surfaces of both gear shift lever case (7) and rear case, and with sealant "C" applied to mating surface of gear shift lever case, push both cases together.
1. "C": Sealant 99000-31110
Tighten gear shift lever case bolts to specification along with transfer rear cover (8) (if equipped) and transfer damper bracket (9).
Tightening torque

Gear shift lever case bolt (j): 13 N.m (1.3 kg-m, 9.5 lb-ft)

Fig 41: Tightening Gear Shift Lever Case Bolts
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Install gear shift control lever temporarily and check to make sure that it shifts to each shift position smoothly. Also check shaft for rotation.
Confirm 4WD switch (2) terminals have continuity at 4WD position (4H and 4L) by using ohmmeter (1).

Fig 42: Checking 4WD Switch Continuity
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For A/T model, confirm 4WD LOW switch terminals are continuity at 4WD LOW and Neutral position.

Fig 43: Identifying Shifter Positions
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Upon completion of above checks, remove shift control lever.