Transfer Assembly: Disassembly and Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

Remove the drain plug and filler plug.
Remove the transfer control device from the rear case.

Fig 1: Locating Transfer Control Device Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the O-ring from the transfer control device.
Remove the self-lock nut from the companion flange using Tool.

Fig 2: Removing Self-Lock Nut
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Tool number: KV40104000 (-)
Put a matching mark on top of the front drive shaft in line with the mark on the companion flange.

Fig 3: Identifying Matching Mark On Top Of Front Drive Shaft And Companion Flange
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft.
Remove the companion flange using suitable tool.

Fig 4: Removing Companion Flange Using Suitable Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove the front oil seal from the front case using Tool.

Fig 5: Removing Front Oil Seal From Front Case
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: ST33290001 (J-34286)

CAUTION: Do not damage front case or front drive shaft.
Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from the front case.

Fig 6: Identifying 4LO Switch And ATP Switch
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Remove the wait detection switch (gray) from the rear case.

Fig 7: Identifying Wait Detection Switch
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Remove check plug, check shift spring and check ball (M/T models only).

Fig 8: Identifying Check Plug, Check Shift Spring & Check Ball (M/T Models Only)
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Remove the dust cover from the rear case, using suitable tool.

Fig 9: Removing Dust Cover From Rear Case
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CAUTION: Do not damage rear case.
Remove oil cover from the dust cover.
Remove the rear oil seal from the rear case using Tool.

Fig 10: Removing Rear Oil Seal
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Tool number: ST33290001 (J-34286)

CAUTION: Do not damage rear case or mainshaft.

Tool number : ST33290001 (J-34286)
Remove the input oil seal from the front case using suitable tool.

Fig 11: Removing Input Oil Seal From Front Case
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not damage front case, sun gear or input bearing.
Remove the retainer bolts and gaskets.

Fig 12: Locating Retainer Bolts And Gaskets
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Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.

Fig 13: Locating Rear Case Bolts
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Separate the front case from the rear case. Then remove the rear case by prying it up using suitable tool.

Fig 14: Removing Rear Case By Prying
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CAUTION: Do not damage the mating surface.
Remove the spacer from the control shift rod (A/T models only).
CAUTION: Do not drop spacer.
Remove the snap ring from the mainshaft using suitable tool.

Fig 15: Removing Snap Ring From Mainshaft Using Suitable Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft rear bearing from the mainshaft using suitable tool.

Fig 16: Removing Mainshaft Rear Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the retainer from the mainshaft.
Remove the snap ring from the mainshaft using suitable tool.

Fig 17: Removing Snap Ring From Mainshaft Using Suitable Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove the oil pump assembly from the mainshaft.
Remove the snap ring from the mainshaft using suitable tool.

Fig 18: Removing Snap Ring From Mainshaft Using Suitable Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove the clutch gear from the mainshaft.
Remove the snap ring from the L-H shift rod assembly using suitable tool.

Fig 19: Removing Snap Ring From L-H Shift Rod Assembly Using Suitable Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.
Remove the drive chain together with the sprocket and front drive shaft from the front case.

Fig 20: Removing Drive Chain With Sprocket And Front Drive Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft from the sun gear assembly.
Remove the L-H shift rod assembly and control shift rod assembly from the front case.
Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.
Remove the snap ring from the sun gear.

Fig 21: Identifying Snap Ring
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CAUTION: Do not damage sun gear or input bearing.
Press the sun gear assembly and planetary carrier assembly from the front case using Tool.

Fig 22: Pressing Sun Gear Assembly And Planetary Carrier Assembly
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: KV38100200 (-)
Remove the snap ring from the front case.

Fig 23: Identifying Snap Ring
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Remove the internal gear from the front case.

Fig 24: Removing Internal Gear
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Remove the snap ring from the front case.

Fig 25: Identifying Snap Ring
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Remove the input bearing from the front case using Tool.

Fig 26: Removing Input Bearing From Front Case Using Tool
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: KV38100200 (-)
Remove the baffle plate from the front case.

Fig 27: Identifying Baffle Plate
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Remove the breather tube from the front case.