Page 1: Table Of Contents
Table of Contents 3- i www.CarGarage.ir Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Front Differential Dismounting and Remounting............3B-3 Precautions............. 3-1 Front Differential Components ......3B-4 Precautions for Driveline / Axle ......3-1 Front Differential Assembly Disassembly Drive Shaft / Axle ........3A-1 and Reassembly ..........3B-5 Front Differential Inspection ......3B-17 Front .................3A-1...
Page 2 3-ii Table of Contents www.CarGarage.ir Input / Output Signal Table of 4WD Control Transfer Assembly Dismounting and Module ............3C-12 Remounting.............3C-57 On-Board Diagnostic System Description..3C-12 Transfer Assembly Components .......3C-58 CAN Communication System Description..3C-13 Transfer Assembly Disassembly and Reassembly ............3C-59 Diagnostic Information and Procedures..3C-14 Transfer Assembly Inspection ......3C-67 4WD Control System Check ......3C-14 Input Gear Assembly, Counter Gear...
Page 3 Table of Contents 3-iii www.CarGarage.ir Repair Instructions ..........3D-2 Tightening Torque Specifications......3D-5 Propeller Shaft Joint Check ........3D-2 Special Tools and Equipment ......3D-6 Propeller Shaft Removal and Installation ....3D-2 Recommended Service Material ......3D-6 Propeller Shaft Disassembly and Assembly ..3D-3 Special Tool ............3D-6 Propeller Shaft Inspection ........3D-5 Specifications............3D-5 www.CarGarage.ir...
Page 4: Precautions
3-1 Precautions: www.CarGarage.ir Precautions Precautions Precautions for Driveline / Axle S5JB0A3000001 Differential Gear Oil Note Refer to “Differential Gear Oil Note: in Section 00”. Fastener Caution Refer to “Fastener Caution: in Section 00”. Precautions for Transfer Refer to “Precautions in Diagnosing Trouble: Motor-Shift Type (Transfer with Shift Actuator) in Section 3C”. www.CarGarage.ir...
Page 5: Drive Shaft / Axle
Drive Shaft / Axle: Front 3A-1 www.CarGarage.ir Drive Shaft / Axle Front General Description Front Drive Shaft Construction S5JB0A3111001 A constant velocity tripod joint is used on the differential side of both the right and left drive shaft assemblies. And, a constant velocity ball joint is used on the wheel side of both the right and left drive shaft assemblies.
Page 6: Repair Instructions
3A-2 Drive Shaft / Axle: Front www.CarGarage.ir Repair Instructions Front Drive Shaft Boot and Joint Check S5JB0A3116001 • Check boot for tear. If even a small tear is found, replace with new one. I5JB0A311001-01 • Check drive shaft joint for wear, breakage, and any other damage. Replace if any abnormality is found. Front Drive Shaft Components S5JB0A3116002 I5JB0A311002-03...
Page 7: Front Drive Shaft Assembly Removal And Installation
Drive Shaft / Axle: Front 3A-3 www.CarGarage.ir Front Drive Shaft Assembly Removal and Installation Installation CAUTION S5JB0A3116003 • Be careful not to damage oil seals and Removal boots when installing drive shaft. 1) Undo caulking (1) and remove drive shaft nut (2). •...
Page 8 3A-4 Drive Shaft / Axle: Front www.CarGarage.ir 2) Wipe off grease from shaft and take off snap ring (1) Assembly using snap ring plier (2). Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly.
Page 9 Drive Shaft / Axle: Front 3A-5 www.CarGarage.ir 5) Apply grease (including in spare parts) to inside of 9) Fasten differential side boot big band. tripod joint housing (1), joint it with tripod joint. • For differential side boot big band Fasten band (1) by drawing hooks (2) with special Grease color tool and engage hooks (3) in slot and window (4).
Page 10: Specifications
3A-6 Drive Shaft / Axle: Front www.CarGarage.ir Specifications Tightening Torque Specifications S5JB0A3117001 NOTE The specified tightening torque is also described in the following. “Front Drive Shaft Components: Front” Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3118001...
Page 11: Rear
Drive Shaft / Axle: Rear 3A-7 www.CarGarage.ir Rear General Description Rear Drive Shaft Construction S5JB0A3121002 Refer to “Front Drive Shaft Construction: Front”. Repair Instructions Rear Drive Shaft Components S5JB0A3126007 I5JB0A312001-02 1. Differential side joint (Constant velocity tripod joint) 5. Boot band (Small) 9.
Page 12: Rear Drive Shaft Assembly Removal And Installation
3A-8 Drive Shaft / Axle: Rear www.CarGarage.ir Rear Drive Shaft Assembly Removal and CAUTION Installation • Protect oil seals and boots from any S5JB0A3126008 Removal damage, preventing them form 1) Undo caulking (1) of drive shaft nut (2) and then unnecessary contact while installing drive remove drive shaft nut.
Page 13: Specifications
Drive Shaft / Axle: Rear 3A-9 www.CarGarage.ir Specifications Tightening Torque Specifications S5JB0A3127001 NOTE The specified tightening torque is also described in the following. “Rear Drive Shaft Components: Rear” Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3128001...
Page 14: Differential
3B-1 Differential: Front www.CarGarage.ir Differential Front General Description Front Differential Construction S5JB0A3211001 The differential assembly uses a hypoid bevel pinion and gear. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory.
Page 15: Repair Instructions
7) Apply sealant to thread of level / filler plug, and then S5JB0A3216012 tighten it to specified torque. 1) Before changing or inspecting oil, be sure to stop “A”: Sealant 99000–31260 (SUZUKI Bond engine and lift vehicle horizontally. No.1217G) 2) With vehicle lifted up, check leakage.
Page 16: Front Differential Unit Components
3B-3 Differential: Front www.CarGarage.ir Front Differential Unit Components S5JB0A3216007 I5JB0A321001-05 1. Front differential 8. Rear mounting bracket bolt 2. Right mounting bracket 9. Damper 3. Right mounting bolt 10. Damper bolt 4. Differential mounting bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 5.
Page 17: Front Differential Components
Differential: Front 3B-4 www.CarGarage.ir Remounting Reverse dismounting procedure for remounting noting the following. • Tighten each bolts and nuts referring to “Front Differential Unit Components: Front”, “Front Drive Shaft Components: Front in Section 3A” and “Front Suspension Frame, Stabilizer Bar and/or Bushings Components: in Section 2B”. •...
Page 18: Front Differential Assembly Disassembly And Reassembly
3B-5 Differential: Front www.CarGarage.ir 9. Differential carrier 25. Rear cover bolt No.2 bolt : Apply sealant 99000-31260 to mating surface of carrier and rear cover. 10. Differential pinion 26. Differential right case 11. Differential gear : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 12.
Page 19 Differential: Front 3B-6 www.CarGarage.ir 5) Support differential side right retainer (1) with soft 8) Remove drive bevel gear (hypoid gear), differential jawed vise and remove oil seal (2) from differential gears, differential pinions and pinion shaft as follows. side right retainer using special tool, if necessary. a) With aluminum plates (2) placed on vise first, grip differential case with it and remove drive Special tool...
Page 20 3B-7 Differential: Front www.CarGarage.ir b) Make mating marks (1) on drive bevel pinion and e) Remove drive bevel pinion rear bearing (2) by companion flange. using bearing puller (3) and hydraulic press. CAUTION CAUTION Do not make mating mark on the coupling To avoid rear bearing from being damaged, surface of the flange.
Page 21 Differential: Front 3B-8 www.CarGarage.ir 12) Drive out rear bearing outer race (1) in the same 2) After applying differential oil to differential gear (4), manner as Step 11). pinions (5), pinion shaft (6), pinion washer, thrust washer (2) and spring washer (1), install them in differential right case (3).
Page 22 3B-9 Differential: Front www.CarGarage.ir 5) Install special tool to differential case assembly (2) 7) Press-fit right side bearing (1) with special tools and and check that preload is within specification. If hydraulic press. preload exceeds specified value, check if foreign NOTE matter is caught or gear is damaged.
Page 23 Differential: Front 3B-10 www.CarGarage.ir 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Page 24 3B-11 Differential: Front www.CarGarage.ir 9) Install special tools with bearings (3) and flange (2) 11) Set dial gauge to mounting dummy and make 0 to differential carrier (1). (zero) adjustment on surface plate (1). NOTE NOTE This installation requires no spacer or oil •...
Page 25 14) Select adjusting shim(s) (2) closest to calculated Then apply grease “A” to oil seal lip. value from among the following available sizes and put it in place and then press-fit rear bearing (1). “A”: Grease 99000–25010 (SUZUKI Super Grease A) Special tool (G): 09913–85210 Special tool (H): 09940–53111...
Page 26 3B-13 Differential: Front www.CarGarage.ir 17) While tightening flange nut gradually with special 18) Select differential side bearing shim as follows. tool and power wrench (4 – 10 magnification) (1), set a) Measure dimension “a” and “b” using vernier preload of pinion to specification. caliper.
Page 27 Differential: Front 3B-14 www.CarGarage.ir 19) To measure bevel gear backlash, set dial gauge (1) 22) As final step, check gear tooth contact as follows. at right angle to bevel gear tooth, fix drive bevel a) After cleaning 10 drive bevel gear teeth, paint pinion and read dial gauge while moving bevel gear.
Page 28 3B-15 Differential: Front www.CarGarage.ir Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
Page 29 (1) as shown in figure. Distance between retainer surface and oil seal “a”: 0.65 – 1.65 mm (0.026 – 0.065 in.) “A”: Grease 99000–25010 (SUZUKI Super Grease A) I5JB0A321042-01 Special tool 25) Assembly front drive shaft retainer as follows.
Page 30: Front Differential Inspection
Rear mounting bracket bolt (a): 50 N·m (5.0 kgf- with carrier and rear cover, and then tighten bolts to m, 36.5 lb-ft) specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Retainer bolt: 50 N·m (5.0 kgf-m, 36.5 lb-ft) “A”...
Page 31: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3218001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 32 3B-19 Differential: Front www.CarGarage.ir 09913–75510 09913–75520 Bearing installer Bearing installer 09913–75821 09913–85210 Bearing installer attachment Bearing installer 09922–66021 09922–75222 Flange holder Differential gear preload adjuster 09922–76520 09924–74510 Bevel pinion gauge block Bearing and oil seal handle 09924–84510–004 09924–84510–005 Bearing installer attachment Bearing installer attachment 09925–14520 09925–86010...
Page 33 Differential: Front 3B-20 www.CarGarage.ir 09928–06510 09930–30104 Differential torque checking Sliding shaft tool 09940–53111 09941–64511 Differential side bearing Bearing and oil seal remover installer (30 mm Min.) 09951–16070 09951–16090 Shim adjuster attachment Oil seal installer 09951–18210 09951–46010 Oil seal remover & installer Drive shaft oil seal installer No.
Page 34: Rear
3B-21 Differential: Rear www.CarGarage.ir Rear General Description Rear Differential Construction S5JB0A3221001 Refer to “Front Differential Construction: Front”. Diagnostic Information and Procedures Rear Differential Symptom Diagnosis S5JB0A3224001 Refer to “Front Differential Symptom Diagnosis: Front”. Repair Instructions Rear Differential Oil Change S5JB0A3226010 Refer to “Front Differential Oil Change: Front”.
Page 35: Rear Differential Dismounting And Remounting
Differential: Rear 3B-22 www.CarGarage.ir Rear Differential Dismounting and Remounting d. Remove rear suspension frame mount front S5JB0A3226012 bolts (1). Dismounting 1) Lift up vehicle and drain oil from rear differential. 2) Remove rear propeller shaft referring to “Propeller Shaft Removal and Installation: in Section 3D”. 3) Remove exhaust center pipe referring to “Exhaust System Components: in Section 1K”.
Page 36: Rear Differential Components
3B-23 Differential: Rear www.CarGarage.ir • Tighten rear suspension frame front and rear bolts to Remounting Reverse dismounting procedure for remounting noting specified torque referring to “Rear Suspension the following. Construction: in Section 2C”. • Tighten rear differential mounting front and rear bolts •...
Page 37: Rear Differential Assembly Disassembly And Reassembly
Differential: Rear 3B-24 www.CarGarage.ir 8. Flange nut 25. Rear cover bolt No.2 bolt : After tightening nut so as rotation torque of bevel pinion shaft to be in specified value, caulk nut securely. 9. Differential carrier 26. Dynamic damper (if equipped) 10.
Page 38 3B-25 Differential: Rear www.CarGarage.ir 5) Disassembly rear drive left retainer in the same b) Remove pinion shafts (1), differential gears, manner at Step 4), if necessary. washers, differential pinions, spring washers, thrust washers and pinion joint. 6) Take out differential assembly (1), outer race and shim all at once.
Page 39 Differential: Rear 3B-26 www.CarGarage.ir I1JA01322006-01 I5JB0A321017-02 1. Drive bevel pinion d) Remove drive bevel pinion (1) with rear bearing, shim and spacer from carrier. 10) Remove oil seal (1) using special tool. If it is hard to remove, screw an used nut (2) into drive bevel pinion and hammer (3) on that nut Special tool with a plastic hammer but never directly on drive...
Page 40 3B-27 Differential: Rear www.CarGarage.ir Reassembly 2) After applying differential oil to differential gear (4), Judging from faulty conditions noted before disassembly pinions (5), pinion shafts (6), pinion washer, thrust and what is found through visual check of bearing and washer (2) and spring washer (1), install them in gear tooth etc.
Page 41 Differential: Rear 3B-28 www.CarGarage.ir 5) Install special tool to differential case assembly (2) 7) Press-fit right side bearing (1) with special tools and and check differential gear for preload. If preload hydraulic press. exceeds specified value, check if foreign matter is NOTE caught or gear is damaged.
Page 42 3B-29 Differential: Rear www.CarGarage.ir 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Page 43 Differential: Rear 3B-30 www.CarGarage.ir 9) Install special tools with bearings (3) and flange (2) 11) Set dial gauge to mounting dummy and make 0 to differential carrier (1). (zero) adjustment on surface plate (1). NOTE NOTE This installation requires no spacer or oil •...
Page 44 102 mm / “a” + “b” Then apply grease “A” to oil seal lip. 4.0157 in. “A”: Grease 99000–25010 (SUZUKI Super 14) Select adjusting shim(s) (2) closest to calculated Grease A) value from among the following available sizes and Special tool put it in place and then press-fit rear bearing (1).
Page 45 Differential: Rear 3B-32 www.CarGarage.ir 17) While tightening flange nut gradually with special 18) Select differential side bearing shim as follows. tool and power wrench (4 – 10 magnification) (1), set a) Measure dimension “a” and “b” using vernier preload of pinion to specification. caliper.
Page 46 3B-33 Differential: Rear www.CarGarage.ir 19) To measure bevel gear backlash, set dial gauge (1) 22) As final step, check gear tooth contact as follows. at right angle to bevel gear tooth, fix drive bevel a) After cleaning 10 drive bevel gear teeth, paint pinion and read dial gauge while moving bevel gear.
Page 47 Differential: Rear 3B-34 www.CarGarage.ir Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
Page 48 3B-35 Differential: Rear www.CarGarage.ir 23) Upon completion of gear tooth contact check in Step b) Install snap ring. 22), caulk flange nut (2) with caulking tool (1) and hammer. I5JB0A322010-01 c) Install oil seal using special tools as shown in figure.
Page 49: Rear Differential Inspection
27) Clean mating surface of right retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover “A”: Sealant 99000–31260 (SUZUKI Bond as shown in figure by such amount that its section is No.1217G) 1.5 mm (0.059 in.) in diameter, mate right retainer...
Page 50: Special Tools And Equipment
3B-37 Differential: Rear www.CarGarage.ir Special Tools and Equipment Recommended Service Material S5JB0A3228001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110...
Page 51 Differential: Rear 3B-38 www.CarGarage.ir 09924–84510–004 09924–84510–005 Bearing installer attachment Bearing installer attachment 09925–14520 09925–86010 Bearing and oil seal installer Bearing puller attachment (80 x 50 mm) 09925–88210 09926–78311–002 Bearing puller attachment Pinion mounting dummy 09926–78311 09926–78320 Differential bevel pinion Mounting dummy dummy 09928–06510 09930–30104...
Page 52 3B-39 Differential: Rear www.CarGarage.ir 09951–18210 09951–46010 Oil seal remover & installer Drive shaft oil seal installer No. 2 www.CarGarage.ir...
Page 53: Transfer
• Diagnostic information stored in 4WD control module memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its I5JB0A331107-03 3) Pour specified oil into transfer up to lever plug hole if Operator’s (Instruction) Manual carefully to have good...
Page 54: Transfer Shift Control System Components
3C-2 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir The transfer has such a selective mechanism as to enable the shift actuator to make selection of high speed (direct connection with transmission output: main shaft), low speed (speed reduction by input gear, counter gear and low gear) or neutral by way of the reduction shift sleeve located between the input gear and low gear, and selection of center differential lock or not by way of the differential lock clutch sleeve located at the center of the rear output shaft.
Page 55: 4Wd Control System Description
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-3 www.CarGarage.ir 1. Transfer switch 4. N indicator 7. Center differential lock switch 2. Differential lock indicator 5. 4WD control module 8. 4L/N switch 3. 4L indicator 6. Transfer actuator 4WD Control System Description S5JB0A3311002 Transfer Shift Control The 4WD control module controls the transfer shift actuator based on the signal from the transfer switch so that the...
Page 56 3C-4 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Operation Condition Indicator Buzzer • Ignition switch is OFF. — • Transfer is at 4H/N position. • Within 2 seconds after ignition switch is turn ON (checking indicator operation). — • Transfer is at 4H-lock/4L-lock position. Flashes at 0.25 Sounds at 1 seconds for 3...
Page 57: Function Of 4Wd Control System Component
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-5 www.CarGarage.ir Function of 4WD Control System Component S5JB0A3311003 Part Name Function Detects transfer shift position combining center differential lock 4L/N switch switch. Center differential lock switch Detects transfer shift position combining 4L/N switch. Transfer switch Shifts transfer shift position.
Page 58 3C-6 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir I5JB0A332003-02 [A]: Transfer position indicator 5. Shift cam 11. Front drive shaft [B]: Transfer switch 6. High / Low shift fork 12. Front drive sprocket 1. 4L/N switch 7. Differential lock shift fork 13.
Page 59 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-7 www.CarGarage.ir The driving force from the transmission is transmitted from the transfer input gear to the rear output shaft, as in the case of 4H position. Also, as the front drive shaft and front drive sprocket bush are engaged via differential lock clutch sleeve, the driving force from the input gear is locked and transmitted to the rear output shaft.
Page 60 3C-8 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir N (Neutral) Position When N position is selected from 4H position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “A”. The shift cam shifts the High / Low shift fork in the arrow direction “B”, and the reduction shift sleeve moves in the arrow direction “B”.
Page 61 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-9 www.CarGarage.ir [A]: Transfer position indicator 4. Shift fork pin 9. Reduction shift sleeve [B]: Transfer switch 5. Shift cam 10. Differential lock clutch sleeve 1. 4L/N switch 6. High / Low shift fork 11.
Page 62 3C-10 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir I5JB0A332006-02 [A]: Transfer position indicator 6. High / Low shift fork 13. Rear output shaft [B]: Transfer switch 7. Differential lock shift fork 14. Center LSD case 1. 4L/N switch 8. Input gear 15.
Page 63: 4Wd Control System Wiring Circuit Diagram
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-11 www.CarGarage.ir 4WD Control System Wiring Circuit Diagram S5JB0A3311006 E91-18 LT GRN G59-2 C54-1 E91-2 E91-19 BLU/BLK G59-3 C54-4 E91-3 E91-20 BLU/ORN G59-4 C54-2 E91-25 C54-3 E91-26 RED/BLK C54-5 BLK/YEL E91-24 PNK/WHT E91-13 E91-14 RED/GRN BLK/ORN...
Page 64: Terminal Arrangement Of 4Wd Control Module
3C-12 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Terminal Arrangement of 4WD Control Module S5JB0A3311007 I4JA01332038-01 [A]: Connector “E91” viewed from harness side Terminal Circuit Terminal Circuit E91-1 Ground E91-18 Transfer switch 1 E91-2 Transfer actuator motor 1 E91-19 Transfer switch 2 E91-3 Transfer actuator motor 2...
Page 65: Can Communication System Description
• DTC can be checked by either one of the following ways. – DTC can be checked by using SUZUKI scan tool (4) connected to DLC (5). – If equipped with diagnosis connector, DTC can be displayed on digital display odometer by shorting diagnosis connector (6).
Page 66: Diagnostic Information And Procedures
3C-14 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir 4WD Control Module Reception Data ABS hydraulic unit / control module Engine speed Vehicle speed Brake pedal switch active Transmission gear selector position Wheel speed pulse (front right) control Receive DATA Wheel speed pulse module (front left)
Page 67 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-15 www.CarGarage.ir Step Action Rechecking and record of DTC / freeze frame data Go to Step 9. Go to Step 10. 1) Recheck for DTC referring to “DTC Check: Motor-Shift Type (Transfer with Shift Actuator)”. Is there any DTC(s)? 4WD control symptom diagnosis Go to Step 11.
Page 68 3C-16 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Customer questionnaire (Example) Customer’s name: Model: VIN: Date of issue: Date of Reg: Date of problem: Mileage: Transfer position indicator abnormal: fails to turn on / fails to turn off / flashes Abnormal noise while vehicle running: from transfer, from actuator, other...
Page 69: Transfer Position Indicator Operation Check
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-17 www.CarGarage.ir Step 5. Trouble symptom confirmation 4WD Control System Operation Inspection Check trouble symptoms based on information obtained S5JB0A3314038 NOTE in “Step 1: Customer complaint analysis: Motor-Shift Type (Transfer with Shift Actuator)” and “Step 2. DTC / •...
Page 70: Visual Inspection
3C-18 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir e) Check that 4L indicator blink, and then e) Check that differential lock indicator blinks, and differential lock indicator and 4L indicator comes then not comes ON. ON steady. 5) Inspect shift operation from 4H to N as follows. 3) Inspect shift operation from 4L-lock to 4H-lock as a) Stop vehicle completely with engine running.
Page 71: Dtc Check
I5JB0A332012-01 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between SUZUKI scan tool and...
Page 72: Dtc Clearance
1) Turn ignition switch to OFF position. the following cases. Be careful not to clear 2) Connect SUZUKI scan tool to data link connector them before keeping their record. (DLC) (1) located on underside of instrument panel.
Page 73: Fail-Safe Table
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-21 www.CarGarage.ir Transfer Detecting condition DTC No. Detecting item position (DTC will set when detecting) indicators Though actuator position switch is “4L-lock” C1228 4L/N switch circuit short position, the OFF signal is not input from the 4L/ N switch.
Page 74: Scan Tool Data
3C-22 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Scan Tool Data S5JB0A3314009 Normal Condition / Scan Tool Data Vehicle Condition Reference Value Vehicle speed At vehicle stop 0 km/h, 0 mph Engine speed At engine idle speed Engine idle speed is display Transfer shifted to 4H position Transfer being shifted between 4H-lock and 4H position 4H-lock –...
Page 75: 4Wd Control Symptom Diagnosis
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-23 www.CarGarage.ir Warning buzzer (OFF / N Pos / Error): Mode switch 2 (Transfer switch) (ON / OFF): ON: Transfer switch to other than 4L-lock position. This parameter indicates if buzzer is being OFF: Transfer switch to 4L-lock position.
Page 76: Transfer Position Indicator Does Not Come On At Ignition Switch On But Engine Stops
3C-24 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Condition Possible cause Correction / Reference Item Gear slipping out of mesh Worn control cover shift shaft Check control cover shift shaft referring to “Transfer Assembly Inspection: Motor-Shift Type (Transfer with Shift Actuator)”. Worn shift fork or sleeve Check shift fork or sleeve referring to “Transfer Assembly Inspection: Motor-Shift Type...
Page 77 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-25 www.CarGarage.ir [A]: 4WD control module connector “E91” (viewed from harness side) 4. 4L indicator [B]: Combination meter connector (viewed from harness side) 5. N indicator 1. 4WD control module 6. Junction block assembly 2.
Page 78: Transfer Position Indicator Remains On Steady At Ignition Switch On
3C-26 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Transfer Position Indicator Remains ON Steady at Ignition Switch ON S5JB0A3314040 Wiring Diagram G28-15 PPL/RED BLK/YEL G28-13 WHT/GRN G28-10 E91-22 G28-8 E91-23 2221201918 1615141312 I5JB0A332015-03 [A]: 4WD control module connector “E91” (viewed from harness side) 4.
Page 79: Dtc C1213: Transfer Switch Circuit Open
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-27 www.CarGarage.ir DTC C1213: Transfer Switch Circuit Open S5JB0A3314041 Wiring Diagram E91-18 LT GRN G59-2 E91-19 BLU/BLK G59-3 G59-4 E91-20 BLU/ORN I5JB0A332016-01 [A]: 4WD control module connector “E91” (viewed from harness side) 1. 4WD control module [B]: Transfer switch connector “G59”...
Page 80: Dtc C1214: Transfer Switch Circuit Short
3C-28 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Step Action Transfer switch check Substitute a known- Replace transfer switch. good 4WD control 1) Check transfer switch referring to “Transfer Switch module and recheck. Inspection: Motor-Shift Type (Transfer with Shift Actuator)”.
Page 81 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-29 www.CarGarage.ir DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Select transfer switch to “4H” position and keep its position for 10 seconds. Similarly select transfer switch to “4H- lock”, “N” and “4L-lock” position. 3) Check DTC.
Page 82: Dtc C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open
3C-30 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open S5JB0A3314043 Wiring Diagram C54-1 E91-2 C54-4 E91-3 C54-2 E91-25 C54-3 E91-26...
Page 83 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-31 www.CarGarage.ir Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Transfer shift actuator motor position switch circuit Go to Step 3.
Page 84: Dtc C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short
3C-32 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short S5JB0A3314044 Wiring Diagram C54-1 E91-2 C54-4 E91-3 C54-2 E91-25 C54-3 E91-26...
Page 85 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-33 www.CarGarage.ir Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Transfer shift actuator motor position switch circuit Go to Step 3.
Page 86: Dtc C1227: 4L/N Switch Circuit Open
3C-34 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir DTC C1227: 4L/N Switch Circuit Open S5JB0A3314045 Wiring Diagram PNK/WHT E91-13 E91-14 RED/GRN I5JB0A332018-01 [A]: 4WD control module connector “E91” (viewed from harness side) 3. 4L/N switch 1. 4WD control module 4.
Page 87: Dtc C1228: 4L/N Switch Circuit Short
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-35 www.CarGarage.ir Step Action 4L/N switch check Substitute a known- Replace 4L/N switch. good 4WD control 1) Check 4L/N switch referring to “Transfer Assembly module and recheck. Inspection: Motor-Shift Type (Transfer with Shift Actuator)”.
Page 88 3C-36 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. 4L/N switch circuit check Go to Step 3. Go to Step 4.
Page 89: Dtc C1230: Transfer Actuator Circuit Malfunction
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-37 www.CarGarage.ir DTC C1230: Transfer Actuator Circuit Malfunction S5JB0A3314047 Wiring Diagram C54-1 E91-2 E91-3 C54-4 C54-2 E91-25 C54-3 E91-26 RED/BLK C54-5 BLK/YEL E91-24 I5JB0A332017-01 [A]: 4WD control module connector “E91” (viewed from harness side) 2.
Page 90: Dtc C1237: Center Differential Lock Switch Circuit Open
3C-38 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Step Action Transfer shift actuator circuit check Go to Step 3. Go to Step 4. 1) Disconnect transfer shift actuator connector “C54” with ignition switch OFF. 2) Check for proper connection to “C54-1” and “C54-4” terminals of transfer shift actuator connector.
Page 91 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-39 www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Though transfer shift actuator motor position switch is “4H” • Center differential lock switch position, the ON signal is not input from the center differential •...
Page 92: Dtc C1238: Center Differential Lock Switch Circuit Short
3C-40 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir DTC C1238: Center Differential Lock Switch Circuit Short S5JB0A3314049 Wiring Diagram PNK/WHT E91-13 E91-14 RED/GRN I5JB0A332018-01 [A]: 4WD control module connector “E91” (viewed from harness side) 3. 4L/N switch 1. 4WD control module 4.
Page 93: Dtc C1240: 4Wd Control Module Power Supply Circuit Malfunction
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-41 www.CarGarage.ir Step Action Center differential lock switch check Substitute a known- Replace center good 4WD control differential lock switch. 1) Check center differential lock switch referring to module and recheck. “Transfer Assembly Inspection: Motor-Shift Type (Transfer with Shift Actuator)”.
Page 94: Dtc C1243: Internal Circuit Malfunction Of 4Wd Control Module
3C-42 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area 4WD control module power supply voltage is out of specification • 4WD control module power supply circuit while vehicle is running at 20 km/h (12 mph) or more. DTC Confirmation Procedure 1) Clear DTC using scan tool.
Page 95: Dtc C1246: Clutch Pedal Position (Cpp) Switch Circuit Short
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-43 www.CarGarage.ir DTC C1246: Clutch Pedal Position (CPP) Switch Circuit Short S5JB0A3314051 Wiring Diagram BLK/ORN E91-7 I5JB0A332020-01 [A]: 4WD control module connector “E91” (viewed from harness side) 2. 4WD control module 1. CPP switch DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 96: Dtc U1073: Control Module Communication Buss Off
3C-44 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Step Action Wire harness check Substitute a known- “BLK/ORN” wire is good 4WD control shorted to ground 1) Disconnect connector from 4WD control module module and recheck. circuit. connector “E91” with ignition switch OFF. 2) Check for proper connection to “E91-7”...
Page 97 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-45 www.CarGarage.ir [A]: Keyless start control module connector (if equipped) (viewed from harness side) 1. BCM [B]: ECM connector (viewed from harness side) 2. 4WD control module [C]: TCM connector (for A/T model) (viewed from harness side) 3.
Page 98: Dtc U1100: Lost Communication With Ecm
3C-46 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Step Action Check DTC Check 4WD control Check applicable module power and control module power 1) Turn ignition switch to OFF position. ground circuit. If circuits and ground circuit. If 2) Disconnect each connector. are OK, substitute a circuit is OK, substitute •...
Page 99 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-47 www.CarGarage.ir [A]: Keyless start control module connector (if equipped) (viewed from harness side) 1. BCM [B]: ECM connector (viewed from harness side) 2. 4WD control module [C]: TCM connector (for A/T model) (viewed from harness side) 3.
Page 100: Dtc U1101: Lost Communication With Tcm
3C-48 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir DTC U1101: Lost Communication with TCM S5JB0A3314054 Wiring Diagram G31-2 G31-4 G31-1 G31-3 WHT/RED E23-4 WHT/BLU E23-19 E91-22 E91-23 WHT/BLU E03-8 E03-10 WHT/RED E92-17 RED E03-12 E92-7 E03-6 G44-19 G28-10 G44-18 G28-8 2221201918 1615141312...
Page 101 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-49 www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for TCM is detected for • CAN communication circuit longer than specified time continuously. • TCM •...
Page 102: Dtc U1121: Lost Communication With Abs Hydraulic Unit / Control Module
3C-50 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir DTC U1121: Lost Communication with ABS Hydraulic Unit / Control Module S5JB0A3314055 Wiring Diagram G31-2 G31-4 G31-1 G31-3 WHT/RED E23-4 WHT/BLU E23-19 E91-22 E91-23 WHT/BLU E03-8 E03-10 WHT/RED E92-17 RED E03-12 E92-7 E03-6 G44-19...
Page 103: Inspection Of 4Wd Control Module And Its Circuits
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-51 www.CarGarage.ir DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ABS hydraulic unit / • CAN communication circuit control module is detected for longer than specified time •...
Page 104 3C-52 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Voltage and Signal Check 1) Check voltage using voltmeter (1) connected to each terminal of couplers. 2) Check signal using oscilloscope (2) connected to each terminal of couplers. NOTE • As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when ignition switch is turned ON.
Page 105 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-53 www.CarGarage.ir Terminal Wire Normal Circuit Condition Number Color Voltage E91-9 — — — — E91-10 Ground 0 – 1 V — Power source for E91-11 10 – 14 V — internal memory E91-12 BLK/WHT Ignition switch 10 –...
Page 106: Repair Instructions
: 1.5 liters (3.2/2.6 US/lmp. pt) 7) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Transfer oil level / filler plug (b): 23 N·m (2.3 kgf- m, 17.0 lb-ft)
Page 107: Transfer Oil Seal Removal And Installation
1) Install new oil seal using special tool and plastic 7A”, and then remove transfer switch (1) from center hammer, and then apply grease to oil seal lip. cluster (2). : Grease 99000–25010 (SUZUKI Super Grease Special tool (A): 09913–70123 I5JB0A331003-02 Installation Reverse removal procedure.
Page 108: Transfer Switch Inspection
3C-56 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Transfer Switch Inspection 4WD Control Module Removal and Installation S5JB0A3316039 S5JB0A3316038 Check continuity between following terminals when Removal transfer switch (1) operated at each position. 1) Disconnect negative (–) cable from battery. Switch position Terminal 2) If the vehicle is equipped with air bag system,...
Page 109: Transfer Assembly Dismounting And Remounting
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-57 www.CarGarage.ir Transfer Assembly Dismounting and 10) Remove gear shift control lever rear case from transfer (for M/T model). Remounting S5JB0A3316040 11) Remove transfer to transmission bolts (upper side), Dismounting and then install engine rear mounting member with 1) Shift transfer to 4H position operating transfer transmission and transfer.
Page 110: Transfer Assembly Components
3C-58 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Transfer Assembly Components S5JB0A3316041 1217G 1217G 1217G 1322 1217G I5JB0A331009-06 www.CarGarage.ir...
Page 111: Transfer Assembly Disassembly And Reassembly
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-59 www.CarGarage.ir 1. Front oil seal No.1 20. Washer 39. Oil strainer : Apply grease 99000-25010 to oil seal lip. 2. Front case bolt 21. Shim 40. Oil strainer bolt 3. Front case 22.
Page 112 3C-60 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir 6) Remove front case (1) using plastic hammer. 9) Remove needle bearings (1) from center case (2) using special tools, if necessary. Special tool (A): 09913–76010 (B): 09925–98210 I5JB0A331014-01 7) Remove rear case bolts (1) and clamp (2) and then separate center case (3) using special tool.
Page 113 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-61 www.CarGarage.ir 16) Remove snap ring (1), and then remove rear output 12) Remove needle bearings (1), front drive shaft (2) and thrust needle bearing (4) from rear output shaft shaft assembly (2) from rear case (3). (3).
Page 114 Reassembly 1) Install new front oil seal No.2 to front case (1) using special tool, and then apply grease to oil seal lip. 1, (a) : Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–85210 I5JB0A331035-03 I5JB0A331033-01 www.CarGarage.ir...
Page 115 5) Install new rear oil seal (1) to rear case (2) using special tool as shown in figure, and then apply grease to oil seal lip. “A”: Grease 99000–25010 (SUZUKI Super Grease A) Distance between case and oil seal “a”...
Page 116: Distance Between Case And Needle Bearing "A" : 0 - 0.5 Mm (0 - 0.008 In.)
3C-64 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir 11) Install low gear (3), center differential (4) and 13) Remove used snap ring, and then install new snap reduction shift sleeve (1) to rear output shaft (2). ring (2) and needle bearing (1) to rear output shaft (3).
Page 117 (2) to specified grease to oil seal lip. torque. Distance between case and oil seal “a” “A”: Sealant 99000–31260 (SUZUKI Bond : 3.5 – 4.5 mm (0.138 – 0.177 in.) No.1217G) “A”: Grease 99000–25010 (SUZUKI Super...
Page 118 1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolts (3) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Oil pump cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 “A”...
Page 119: Transfer Assembly Inspection
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-67 www.CarGarage.ir Transfer Assembly Inspection • Assemble front drive shaft (1), front drive sprocket (2) S5JB0A3316043 and differential lock clutch sleeve (3), check whether • Check needle bearing and bearing contacting surface differential lock clutch sleeve moves smoothly, and for damage.
Page 120 3C-68 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir • Check 4L/N switch and center differential lock switch • Operate the motor, and measure the resistance for continuity between “a” and “b” terminals of switch. between following terminals of transfer actuator when If check result is not as specified below, replace matching transfer actuator (1) to 4H-lock position and switch.
Page 121: Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly And Rear Output Shaft Assembly Components
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-69 www.CarGarage.ir Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components S5JB0A3316044 I5JB0A331061-02 1. Snap ring 6. Counter gear 2. Bearing 7. Front output shaft 3. Input gear plate : Do not reuse.
Page 122: Input Gear Assembly Disassembly And Reassembly
3C-70 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Input Gear Assembly Disassembly and 2) Install input gear plate (1), and then press-fit bearing (2) using special tool, bearing puller (3) and press Reassembly (4). S5JB0A3316045 Disassembly NOTE 1) Remove snap ring (1) from input gear, and then Assemble bearing so that seal side (5) may remove bearing (2).
Page 123: Counter Gear Assembly Disassembly And Reassembly
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-71 www.CarGarage.ir Counter Gear Assembly Disassembly and 3) Install snap ring (1) to counter gear (2). Reassembly S5JB0A3316046 Disassembly 1) Remove snap ring (1) from counter gear (2). I5JB0A331068-01 Front Output Shaft Assembly Disassembly and Reassembly S5JB0A3316047 I5JB0A331068-01...
Page 124: Rear Output Shaft Assembly Disassembly And Reassembly
3C-72 Transfer: Motor-Shift Type (Transfer with Shift Actuator) www.CarGarage.ir Rear Output Shaft Assembly Disassembly and Reassembly Reassembly 1) Clean all components thoroughly, inspect them for S5JB0A3316048 any abnormality and replace with new ones as necessary. Disassembly 2) Press-fit bearing (1) to front output shaft using 1) Remove snap ring (1) from rear output shaft (2).
Page 125: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3318001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 126 Bearing installer 09928–36510 09940–54910 Transfer cap Front fork oil seal install driver SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7.
Page 127: Non-Shift Type (Transfer Without Shift Actuator)
Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-75 www.CarGarage.ir Non-Shift Type (Transfer without Shift Actuator) Precautions Transfer Warning S5JB0A3320001 Refer to “Transfer Warning: Motor-Shift Type (Transfer with Shift Actuator)”. General Description Transfer Construction S5JB0A3321001 The aluminum transfer case directly connected to the back of the transmission contains the input gear, rear output shaft, front output shaft and drive chain.
Page 128: Diagnostic Information And Procedures
3C-76 Transfer: Non-Shift Type (Transfer without Shift Actuator) www.CarGarage.ir Diagnostic Information and Procedures Transfer Symptom Diagnosis S5JB0A3324001 Before attempting to repair the transfer or related components for any reason other than mechanical failure, the condition and possible causes should be identified. When any of these conditions occur, the following inspections should be made before disassembling the transfer.
Page 129: Repair Instructions
Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-77 www.CarGarage.ir Repair Instructions Transfer Oil Change S5JB0A3326002 Refer to “Transfer Oil Change: Motor-Shift Type (Transfer with Shift Actuator)”. Transfer Oil Level Check S5JB0A3326003 Refer to “Transfer Oil Level Check: Motor-Shift Type (Transfer with Shift Actuator)”. Transfer Oil Seal Removal and Installation S5JB0A3326004 Refer to “Transfer Oil Seal Removal and Installation: Motor-Shift Type (Transfer with Shift Actuator)”.
Page 130: Transfer Assembly Components
3C-78 Transfer: Non-Shift Type (Transfer without Shift Actuator) www.CarGarage.ir Transfer Assembly Components S5JB0A3326006 1217G 1217G 1217G 1217G I5JB0A331084-05 www.CarGarage.ir...
Page 131 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-79 www.CarGarage.ir 1. Front oil seal No.1 17. Differential lock clutch sleeve 33. Oil drain plug : Apply grease 99000-25010 to oil seal lip. : Apply sealant 99000-31260 to plug thread. 2. Front case bolt 18.
Page 132: Transfer Assembly Disassembly And Reassembly
3C-80 Transfer: Non-Shift Type (Transfer without Shift Actuator) www.CarGarage.ir Transfer Assembly Disassembly and 5) Remove rear case bolts (1), and then separate center case (2) using special tool. Reassembly S5JB0A3326007 Special tool Disassembly (A): 09912–34510 1) Remove differential lock shift lever case (1). I5JB0A331087-01 I5JB0A331085-01 2) Remove oil pump cover (1).
Page 133: Assembly (2), Drive Chain (3) And Needle Bearing (4
Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-81 www.CarGarage.ir 8) Remove needle bearing (1), snap ring (2), washer 12) Remove front drive sprocket bush (1) from rear (3) and shim(s) (4) from rear output shaft (5). output shaft (2). I5JB0A331089-01 I5JB0A331023-01 9) Remove reduction shift sleeve (1) and center 13) Take out front drive sprocket (1), front output shaft...
Page 134 I5JB0A331036-02 5) Install new rear oil seal (1) to rear case (2) using : Grease 99000–25010 (SUZUKI Super Grease A) special tool as shown in figure, and then apply Special tool grease to oil seal lip.
Page 135: Into Rear Case
Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-83 www.CarGarage.ir 9) Install differential lock clutch sleeve (1) to rear output shaft (2) as shown in figure. “a” 1, “A” I5JB0A331094-04 6) Install rear output shaft assembly (2) to rear case (3), I5JB0A331040-01 and then install snap ring (1).
Page 136 Distance between case and oil seal “a” : 3.5 – 4.5 mm (0.138 – 0.177 in.) “A”: Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–70123...
Page 137 (0.047 in.) in diameter, mate front case (3) with case and then tighten bolts (2) to specified torque. center case and then tighten bolts (2) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Rear case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Page 138: Input Gear Assembly Disassembly And Reassembly
1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolts (3) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Oil pump cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 “A”...
Page 139: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3328001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 140: Propeller Shafts
3D-1 Propeller Shafts: www.CarGarage.ir Propeller Shafts Precautions Propeller Shaft Caution S5JB0A3400001 CAUTION • All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 141: Diagnostic Information And Procedures
• Clean and inspect sliding portion of propeller shaft end (where oil seal contacts) before installation and if even small dent or scratch exists, correct end clean it again. Then apply grease inside splines of propeller shaft. “B”: Grease 99000–25010 (SUZUKI Super Grease IYSQ01521009-01 www.CarGarage.ir...
Page 142: Propeller Shaft Disassembly And Assembly
3D-3 Propeller Shafts: www.CarGarage.ir • Install propeller shaft aligning match marks. Propeller Shaft Disassembly and Assembly Otherwise, vibration may occur during driving. S5JB0A3406005 • Use the following specification to torque universal joint CAUTION flange nuts and bolts. For front propeller shaft flange Never disassemble each joint.
Page 143 Propeller Shafts: 3D-4 www.CarGarage.ir NOTE • Take care not to lose rollers in spider bearing race when removing it. • Fit removed bearings temporarily in spider so that they can be reinstalled in their original positions. IYSQ01340008-01 I5JB0A340006-01 Assembly 4) Tapping yoke with a hammer, completely remove bearing race.
Page 144: Propeller Shaft Inspection
4) Insert bearing races on the flange yoke side in the 1) Make sure to apply grease to spider bearing race. same way as described in Step 1) and 2). “A”: Grease 99000–25030 (SUZUKI Super 5) Securely fit 4 circlips to shaft and flange yoke. Grease C) NOTE •...
Page 145: Special Tools And Equipment
Propeller Shafts: 3D-6 www.CarGarage.ir Special Tools and Equipment Recommended Service Material S5JB0A3408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 SUZUKI Super Grease C P/No.: 99000–25030 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110...
Page 146 3D-7 Propeller Shafts: www.CarGarage.ir www.CarGarage.ir...

Suzuki Grand Vitara Service Manual

Precautions

Drive Shaft / Axle

Front

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Rear

General Description

Repair Instructions

Specifications

Special Tools and Equipment

Differential

Front

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Rear

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Transfer

Motor-Shift Type (Transfer with Shift Actuator)

Precautions

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Non-Shift Type (Transfer Without Shift Actuator)

Precautions

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Propeller Shafts

Precautions

General Description

Repair Instructions

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Quick Links

Related Manuals for Suzuki Grand Vitara

Summary of Contents for Suzuki Grand Vitara

Table of Contents