Transfer Assembly Disassembly and Assembly: Disassembly

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

Remove intermediate output oil seal (1) from transfer right case (5).
Remove snap ring (2) by using special tool.
Special Tool

: 09952-76011
Remove intermediate shaft (4) with intermediate shaft bearing (3).
Remove intermediate shaft bearing (3) from intermediate shaft (4) by using bearing puller and press.

Fig 1: Removing Intermediate Shaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove transfer output retainer assembly (1) and shims (3) by removing 4 bolts (2).
Remove 9 transfer case bolts (4).
Separate transfer right case (5) from transfer left case (6) by using special tool.
Special Tool
1. 09912-34510
Remove reduction drive gear assembly (7), reduction idler gear assembly (8) and reduction driven gear assembly (9).
Remove reduction idler gear taper roller bearing outer race (10), shim (11) and reduction driven gear RH taper roller bearing outer race (12) from transfer right case (5).
Remove reduction idler gear taper roller bearing outer race (10), reduction driven gear LH taper roller bearing outer race (13) from transfer left case (6).
NOTE: When it is difficult to remove taper roller bearing outer races from cases, remove them with special tool.

Special Tool
1. (B): 09941-54911
  
  Fig 2: Removing Reduction Drive Gear, Reduction Idler Gear And Reduction Driven Gear Assembly
  Courtesy of SUZUKI OF AMERICA CORP.