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Home >> Suzuki >> 2003 >> Vitara 2D Utility, 4WD, Standard >> Repair and Diagnosis >> Transmission >> Transfer Case >> Repair Instructions >> Transfer Disassembly

Transfer Disassembly

  1. Remove 4WD switch (3) and take out steel ball.
  2. Remove 5 bolts and then remove gear shift lever case (4).
    Fig 1: Removing 4WD Switch
    G01351536Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove bolt of select return system and then take out spring (4), steel ball (5) and pin (6).
    Fig 2: Removing Select Return Spring, Steel Ball & Pin
    G01351537Courtesy of SUZUKI OF AMERICA CORP.
  4. By hammering special tool, drive spring pin out of reduction shift yoke.
    NOTE:
    • Pin may drop into case when drive out. Therefore, take it out when case is disassembled.
    • After spring pin is removed, yoke may be either taken out.
    1. Special tool 
    2. (A):  09922-85811
    Fig 3: Driving Spring Pin Out Of Reduction Shift Yoke
    G01351538Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove 15 rear case bolts and then separate case by using special tool.
    NOTE: To separate center case (1) and rear case (2), use special tool at 4 points in turn and make opening wider evenly.
    1. Special tool 
    2. (B):  09912-34510
    Fig 4: Separating Center Case & Rear Case
    G01351539Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove circlip (1) from output rear shaft (2) by using screwdrivers and hammer, then pull out speedometer drive gear (3) and steel ball.
    Fig 5: Removing Circlip From Output Rear Shaft, Pulling Out Speedometer Drive Gear & Steel Ball
    G01351540Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove circlip for bearing and pull out bearing No. 2 (1) by combination of special tools.
    1. Special tool 
    2. (C):  09921-57810
    3. (D):  09927-18411
    Fig 6: Removing Circlip For Bearing & Pulling Out Bearing No. 2
    G01351541Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove synchronizer plate screws (2) and pull out sprocket bush (4) and needle bearing (3) from output rear shaft (5).
  9. Remove sprocket (6) with drive chain (7) and synchronizer plate (1).
    NOTE: Watch out for steel ball which comes off from shaft when bush is pulled out so as not to lose it.
    Fig 7: Removing Drive Sprocket With Drive Chain
    G01351542Courtesy of SUZUKI OF AMERICA CORP.
  10. Remove counter shaft plate bolt (1) from front case (3), and counter shaft plate will come off.
  11. Remove front case (3) by removing its 9 bolts (2).
    Fig 8: Removing Front Case
    G01351543Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove input gear needle bearing (1). Remove counter gear shaft (3) together with needle bearings, spacer, washers (4) and steel balls (5) from case.
    NOTE:
    • Watch out for steel balls (5) which come out from between shaft (3) and washers (front and rear) (4) so as not to lose them.
    • Check friction ring up for damage and wear. Replace if necessary.
    • Neither O-ring nor friction ring should be removed unless absolutely necessary. If removed, use new parts for reinstallation. Removed ones should not be reused.
    Fig 9: Removing Counter Gear Shaft Together With Counter Gear, Needle Bearings, Function Ring, Washers & Steel Balls
    G01351544Courtesy of SUZUKI OF AMERICA CORP.
  13. Remove O-ring from counter gear shaft (2) and then remove friction ring (3) from shaft, using a proper size rod (1) and hydraulic press.
    Fig 10: Removing O-Ring & Friction Ring From Counter Gear Shaft
    G01351545Courtesy of SUZUKI OF AMERICA CORP.
  14. Remove locating spring bolt (1) with washer (2), spring (3) and ball (4) for reduction shift. Remove rubber plug (5) as well.
  15. Pull out reduction shift shaft (6) together with fork (7) and sleeve (8).
    NOTE: For this removal, be sure to place front drive fork shaft at 4WD position.
    Fig 11: Removing Locating Spring Bolt With Washer, Spring & Ball For Reduction Shift - Removing Rubber Plug
    G01351546Courtesy of SUZUKI OF AMERICA CORP.
  16. Remove locating spring bolt (1) with washer (2), spring (3) and ball (4) for front drive shift.
  17. Pull out front drive shift fork (6) and shaft (5), sleeve (7) and hub (8) all together.
    NOTE: Watch out for interlock steel ball which comes out from between 2 shift shafts so as not to lose it. If it doesn't come out, remove rubber plug and take it out.
    Fig 12: Pulling Out Front Drive Shift Fork & Shaft, Sleeve & Hub
    G01351547Courtesy of SUZUKI OF AMERICA CORP.
  18. Using plastic hammer (2), drive out output rear shaft assembly (1) with bearing. Output low gear and reduction clutch hub also come off as they are installed to shaft.
    Fig 13: Driving Out Output Rear Shaft Assembly With Bearing
    G01351548Courtesy of SUZUKI OF AMERICA CORP.
  19. Pull off circlip from output rear shaft and remove reduction clutch hub (1) by using puller (2) and hydraulic press. Then pull out output low gear and needle bearing.
    Fig 14: Removing Reduction Clutch Hub
    G01351549Courtesy of SUZUKI OF AMERICA CORP.
  20. Using puller (3) and hydraulic press, remove bearing No. 1(2) from shaft (1).
    Fig 15: Removing Output Rear Shaft No. 1 Bearing
    G01351550Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove oil seal from center case (1).
  22. Using plastic hammer, drive out output front shaft (2) together with bearings.
    CAUTION: If oil seal remains in center case, be careful not to damage oil seal by hitting. Use drive punch for hammering.
    Fig 16: Driving Out Output Front Shaft
    G01351551Courtesy of SUZUKI OF AMERICA CORP.
  23. Take off bearings (1, 3) from shaft by using hydraulic press and puller (2). Removal of front side bearing requires special tool additionally as shown in the figure.
    1. Special tool 
    2. (E):  09925-98221
    Fig 17: Removing Bearings From Shaft
    G01351552Courtesy of SUZUKI OF AMERICA CORP.
  24. To remove needle bearing (2) from center case (1), combine special tools as shown in the figure and press them.
    1. Special tool 
    2. (F):  09913-84510
    3. (G):  09941-64511
    Fig 18: Removing Needle Bearing From Center Case
    G01351553Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove oil seal from rear case (1). And then, using same special tools and hydraulic press as in above step, remove needle bearing (2) from rear case.
    CAUTION: Be careful not to damage oil seal, if it remains in rear case.
    1. Special tool 
    2. (F):  09913-84510
    3. (G):  09941-64511
    Fig 19: Removing Oil Seal & Needle Bearing From Rear Case
    G01351554Courtesy of SUZUKI OF AMERICA CORP.
  26. Using special tool, remove circlip (3) of input gear (1) from front case (2).
    NOTE: Be sure to use right tool to ensure proper work.
    1. Special tool 
    2. (H):  09900-06108
    Fig 20: Removing Circlip Of Input Gear From Front Case
    G01351555Courtesy of SUZUKI OF AMERICA CORP.
  27. Using plastic hammer, drive input gear (2) out of front case (1).
    NOTE:
    • Be careful not to damage oil seal (3) by hitting.
    • If removed, do not reuse oil seal.
    Fig 21: Driving Input Gear Out Of Front Case
    G01351556Courtesy of SUZUKI OF AMERICA CORP.
  28. Remove circlip (2) of input gear (1) by using special tool.
    1. Special tool 
    2. (I):  09900-06107
    Fig 22: Removing Circlip Of Input Gear
    G01351557Courtesy of SUZUKI OF AMERICA CORP.
  29. Remove bearing (2) from input gear (1) by using puller (3) and hydraulic press.
    NOTE: Use metal pad for this removal, or gear spline may get damaged.
    1. Special tool 
    2. (J):  09951-76010
    Fig 23: Removing Bearing From Input Gear
    G01351558Courtesy of SUZUKI OF AMERICA CORP.
  30. With spring (3) on front drive fork shaft (4) compressed, remove circlip (1) and then remove fork (2) and spring (3).
    Fig 24: Removing Circlip, Fork & Spring
    G01351559Courtesy of SUZUKI OF AMERICA CORP.
  31. Remove center case gutter (1) from center case (2) with using wrench.
    Fig 25: Removing Center Case Gutter From Center Case
    G01351560Courtesy of SUZUKI OF AMERICA CORP.
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