Transfer Assembly Disassembly and Reassembly: Reassembly

Special Tool 

: 09913-85210 

Special Tool 

1. 09924-74510 
2. 09944-88210 

Fig 1: Installing Oil Seal To Transfer Left Case

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Oil seal (outer) installing depth 

"a": 16 - 17 mm (0.6 - 0.7 in.) 

Special Tool 

: 09925-15410 

Oil seal (inner) installing depth 

"b": 3 - 4 mm (0.1 - 0.2 in.) 

Special Tool 

1. 09925-15410 

Fig 2: Identifying Oil Seal Inner Depth

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: Grease 99000-25011 (SUZUKI Super Grease A) 

• Oil pump inner rotor (1)
• Oil pump outer rotor (2)
• Oil pump outer cover (3)
• Oil pump drive pin (4)

Tightening torque 

Oil pump outer cover bolt (a): 8.0 N.m (0.82 kg-m, 6.0 lbf-ft) 

Fig 3: Identifying Oil Pump Outer Cover Bolts

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Special Tool 

1. 09924-74510 
2. 09924-07730 

Fig 4: Installing Right Bearing To Reduction Driven Gear

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Special Tool 

1. 09924-07710 
2. 09924-84510-005 
3. 09925-15410 

Fig 5: Installing Bevel Gear To Reduction Driven Gear

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Special Tool 

1. 09913-84510 
2. 09924-84510-005 

Fig 6: Installing Left Bearing To Reduction Driven Gear

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Special Tool 

1. 09913-85230 

Fig 7: Installing Bearings To Reduction Drive Gear

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1. Calculate thickness of shim "e" with calculating formula.

   "e" = ("b" + "c") - "a" + 0.1 mm (0.004 in.)

   • "a": distance between outer race end of reduction driven gear bearings (mm (in.))
   • "b": depth of bearing retaining surface on transfer left case (2) (mm (in.))
   • "c": depth of bearing retaining surface on transfer right case (3) (mm (in.))
     Fig 8: Calculating Thickness Of Shim

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2. Select a shim which is close to half thickness of the calculated value (necessary shim thickness) from among the available shims to install it between bearing and case at each of right and left sides.

   Available reduction driven gear left shim (2) thickness 

   REDUCTION DRIVEN GEAR LEFT SHIM THICKNESS SPECIFICATION
   
   

   Select shim
   1.00 mm (0.039 in.)
   1.05 mm (0.041 in.)
   1.10 mm (0.043 in.)
   1.15 mm (0.045 in.)
   1.20 mm (0.047 in.)
   1.25 mm (0.049 in.)
   1.30 mm (0.051 in.)
   1.35 mm (0.053 in.)
   1.40 mm (0.055 in.)

   Available reduction driven gear right shim (4) thickness 

   REDUCTION DRIVEN GEAR RIGHT SHIM THICKNESS SPECIFICATION
   
   

   Select shim
   0.60 mm (0.024 in.)
   0.65 mm (0.026 in.)
   0.70 mm (0.028 in.)
   0.75 mm (0.030 in.)
   0.80 mm (0.031 in.)
   0.85 mm (0.033 in.)
   0.90 mm (0.035 in.)
   0.95 mm (0.037 in.)
   1.00 mm (0.039 in.)
   1.05 mm (0.041 in.)

   Fig 9: Identifying Reduction Driven Gear Left Shim

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   Fig 10: Identifying Reduction Driven Gear Left Bearing Outer Race To Transfer Left Case

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3. Install reduction driven gear (1) to transfer left case (2).
   NOTE: Do not install reduction drive gear yet.
   Fig 11: Identifying Reduction Driven Gear And Transfer Left Case

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4. Install transfer right case (1) to left case and tighten transfer case bolts (2) to specified torque.
   NOTE: Do not apply sealant to mating surface of transfer left case (3) and transfer right case in this stage.

   Tightening torque 

   Transfer case bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

   Fig 12: Identifying Transfer Case Bolts

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5. Install shim (1) selected in TRANSFER OUTPUT RETAINER ASSEMBLY DISASSEMBLY AND REASSEMBLY  and transfer output retainer (2) to transfer case (3) and tighten retainer bolts (4) to specified torque.

   Tightening torque 

   Transfer output retainer bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft) 

   Fig 13: Identifying Transfer Output Retainer, Transfer Case And Retainer Bolts

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6. Use dial gauge to measure play of flange (2) rotative direction. If check result is not specified, change distribution of reduction driven gear right and left shims installed on transfer left case and transfer right case in Step  b) and measure its play again.

   Bevel pinion & bevel gear backlash 

   : 0.1 - 0.2 mm (0.04 - 0.08 in.) 

   Special Tool 

   1. 09900-20607 
   Fig 14: Measuring Play Of Flange Using Dial Gauge

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7. Remove transfer output retainer and inspect teeth contact of bevel gear (1).
   1. After cleaning tooth surface of bevel gear, paint them with gear marking compound evenly by using brush or sponge etc.
   2. Install shim selected in TRANSFER OUTPUT RETAINER ASSEMBLY DISASSEMBLY AND REASSEMBLY  and transfer output retainer to transfer case and tighten retainer bolts to specified torque.

      Tightening torque 

      Transfer output retainer bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft) 

   3. Turn transfer output flange clockwise and counterclockwise repeatedly, and remove transfer output retainer assembly and shim from transfer assembly.
   4. Bring painted part up and check contact pattern referring to the following chart. If contact pattern is not normal, readjust or replace if necessary according to instruction in chart.
      Fig 15: Identifying Transfer Output Retainer And Teeth Contact Of Bevel Gear

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   NOTE:

   • Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.
   • If bevel gear backlash and bevel pinion shims are adjusted properly, correct tooth contact should be provided.

     If correct tooth contact is not provided even when they are adjusted properly, however, there may be an abnormal condition in warm tooth, transfer case or retainer. Check each component and replace if necessary.

   Gear tooth contact table 

   GEAR TOOTH CONTACT PATTERN CHART
   
   

   Tooth contact pattern	Diagnosis and remedy
   Courtesy of SUZUKI OF AMERICA CORP.	Normal
   Courtesy of SUZUKI OF AMERICA CORP.	High contact  Pinion (1) is positioned too far from the center of bevel gear (2). Decrease thickness of transfer output retainer shim and position pinion closer to gear center. Adjust bevel gear backlash to specification.
   Courtesy of SUZUKI OF AMERICA CORP.	Low contact  Pinion (1) is positioned too close to the center of bevel gear (2). Increase thickness of transfer output retainer shim and position pinion farther from gear center. Adjust bevel gear backlash to specification.
   Courtesy of SUZUKI OF AMERICA CORP.	These contact patterns indicate that the "offset" of reduction driven gear is too much or too little. The remedy is to change the division of the reduction driven gear shim(s).
   Courtesy of SUZUKI OF AMERICA CORP.	These contact patterns, located on toe or heel on both drive and coast sides, mean that 1) both pinion and gear are defective, 2) retainer is not true, or 3) gear is not properly seated on transfer case. The remedy is to replace the defective member.
   Courtesy of SUZUKI OF AMERICA CORP.	Irregular patterns: If the pattern is not oval, it means that bevel gear is defective. High or low spots on tooth surfaces or on the seat of bevel gear are the cause of irregular patterns appearing on some teeth. The remedy is to replace the pinion and gear set and, if the seat is defective, so is transfer case.

   CAUTION: Bevel gear and pinion must be replaced as a set when replacement of either one becomes necessary.

"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) 

Fig 16: Identifying Reduction Drive Gear Assembly, Reduction Driven Gear Assembly And Transfer Left Case

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Tightening torque 

Transfer case bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

Fig 17: Identifying Transfer Case Bolts

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Tightening torque 

Transfer output retainer bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft) 

Fig 18: Identifying Transfer Output Retainer, Transfer Case And Retainer Bolts

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