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Transfer Assembly Disassembly and Reassembly: Disassembly

NOTE: It is possible to disassemble transfer assembly without removing intermediate shaft with Step) 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.
    Fig 1: Removing Intermediate Shaft Bearing From Intermediate Shaft
    G06867403Courtesy of SUZUKI OF AMERICA CORP.
  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 

    Fig 2: Removing Reduction Drive Gear Assembly And Reduction Driven Gear Assembly
    G06867404Courtesy of SUZUKI OF AMERICA CORP.
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