Transfer Dismounting and Remounting

Transfer Dismounting and Remounting

Dismounting
1) Disconnect negative (-) cable at battery.
2) Drain the following oils and fluids.
^ Manual transaxle oil (M/T model):
^ CVT fluid (CVT model):
^ Transfer oil:
^ P/S fluid (Hydraulic P/S model):
3) Remove right side drive shaft assembly.
4) Remove propeller shaft.
5) Carry out Step 2) to 13) of "Removal" under Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation (2WD Model).
6) Remove engine rear mounting.
7) Disconnect breather hose (1).
8) Remove transfer stiffener (2), transfer bolts and transfer nut.
9) Separate transfer (3) from transaxle.

CAUTION:
When removing transfer, be careful not to drop it. Otherwise, transfer damage and personal injury may result.





10) Lower front suspension frame with steering gear case and transfer, and then remove transfer.
11) Remove O-ring (1) and dowel pin (2).





Remounting
Reverse dismounting procedure for remounting of transfer, noting the following points.

CAUTION:
Never reuse suspension arm mounting bolt and front suspension frame mounting bolt to prevent it from loosening. Be sure to replace suspension arm bolt and front suspension frame mounting bolt with a new one whenever loosening once.

^ Use new O-ring, drive shaft nut and new cotter pin.
^ Apply grease to left case and O-ring (1) as shown in figure.

"A": Grease 99000-25011 (SUZUKI Super Grease A)





^ Tighten transfer bolts and transfer nut to specified torque.

Tightening torque
Transfer bolt (a): 88 Nm (9.0 kg-m, 65.0 lbf-ft)
Transfer nut (b): 88 Nm (9.0 kg-m, 65.0 lbf-ft)

^ Tighten transfer stiffener bolts to specified torque in numerical order ("1" - "4") evenly and gradually.

Tightening torque
Transfer stiffener bolt * (c): 55 Nm (5.6 kg-m, 40.5 lbf-ft)








^ Tighten the following bolts and nuts to specified torque.
- Engine rear mounting nut:
- Front suspension frame mounting bolt:
- Mounting member nut:
- Suspension arm bolt:
- Stabilizer joint nut:
- Suspension arm ball joint bolt:
- Tie-rod end nut
- Hydraulic P/S model:
- EPS model:
- Front wheel speed sensor bolt
- ABS model:
- ESP(R) model:
- Propeller shaft bolt:
- Center support nut:
- Exhaust pipe bolt:
- Exhaust pipe clamp bolt:
- Exhaust No.1 pipe stiffener bolt:
- Wheel nut:
^ Refill the following oils and fluids.
- Manual transaxle oil (M/T model):
- CVT fluid (CVT model):
- Transfer oil:
^ For hydraulic P/S model, refill P/S fluid and bleed air.
- Refill P/S fluid:
- Bleed air:
^ Verify that there is no oil leakage, fluid leakage and exhaust gas leakage at each connection.
^ Confirm front wheel alignment.