Transfer: Overhaul Suzuki Aerio I

Disassembly

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

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1. Remove intermediate output oil seal (1) from transfer right case (5).
2. Remove snap ring (2) by using special tool. Special Tool : 09952-76011
3. Remove intermediate shaft (4) with intermediate shaft bearing (3).
4. Remove intermediate shaft bearing (3) from intermediate shaft (4) by using bearing puller and press.
5. Remove transfer output retainer assembly (1) and shims (3) by removing 4 bolts (2).
6. Remove 9 transfer case bolts (4).
7. Separate transfer right case (5) from transfer left case (6) by using special tool. Special Tool 09912-34510
8. Remove reduction drive gear assembly (7), reduction idler gear assembly (8) and reduction driven gear assembly (9).
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).
10. 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 (B): 09941-54911

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1. Select appropriate shim as follows. Measure distance "a" between taper roller bearing outer races of reduction idler gear (1). Measure depth "b" of left case (2) and "c" of right case (3). Obtain adjusting shim thickness by the following equation. Necessary shim thickness = Depth "b" + Depth "c" - Distance "a" + 0.05 mm (0.002 in.) Select adjusting shim closest to calculated value from among the following available sizes. Available reduction idler gear shim thickness 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1.00, 1.05, 1.10 and 1.15 mm (0.022, 0.024, 0.026, 0.028, 0.030, 0.031, 0.033, 0.035, 0.037, 0.039, 0.041, 0.043 and 0.045 in.)
2. Clean mating surface of right and left cases, and apply sealant to right case (1) by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. "A": Sealant 99000-31260
3. Assemble the following parts in right and left cases by reversing disassembling procedure. Reduction drive gear assembly (1) Reduction idler gear assembly (2) Reduction driven gear assembly (3) Reduction idler gear taper roller bearing outer races (4) Reduction driven gear RH taper roller bearing outer race (5) Reduction driven gear LH taper roller bearing outer race (6) Reduction idler gear shim (7) Knock pin (8)
4. Tighten 9 transfer case bolts (9) to specified torque. Tightening torque Transfer case bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
5. Perform transfer preload and back lash adjustment as follows. Adjust reduction idler gear taper roller bearing preload as follows. Measure reduction drive gear staring toque (i.e., preload of reduction idler gear taper roller bearings) by using special tool and torque wrench (1). Special Tool 09928-36010 Starting torque of reduction drive gear (reduction idler gear bearing preload) 0.5 - 1.4 N.m (5 - 14 kg-cm, 0.35 - 1.0 lb-ft) If starting torque is out of specification, replace reduction idler gear shim and measure staring torque again. NOTE: Make a record of starting torque of reduction drive gear because it is used for adjusting reduction driven gear taper roller bearing preload. Adjust bevel gear back lash as follows. Install transfer output retainer assembly referring to «TRANSFER ASSEMBLY DISASSEMBLY AND ASSEMBLY»(ref-251077-S37011236932007032000000) . Set torque wrench (1) on transfer output flange nut. Screw bevel gear adjuster (2) on right case until transfer output flange (3) does not rotate by rotational torque with 10-20 N.m (1.0-2.0 kgf-m, 7.5-14.5 lb-ft) by using special tool. Loosen bevel gear adjuster (2) on right case to angle with 24-36° to make backlash between bevel gears. Special Tool 09940-14940 Bevel gear backlash 0.1 - 0.15 mm (0.004 - 0.006 in.) Remove transfer output retainer assembly and bevel gear shims to measure reduction driven gear taper roller bearing preload. Adjust reduction driven gear taper roller bearing preload as follows. Screw bevel gear adjuster (1) on left case by using special tool while measuring starting torque of reduction drive gear (i.e., preload of reduction idler gear and driven gear taper roller bearings) by using special tool and torque wrench (2) until corrected starting torque value of reduction drive gear is in specified value shown as follows. Special Tool 09928-36010 09940-14940 Correct starting torque to starting torque caused by only preload of reduction driven gear taper roller bearings by the following equation. Corrected starting torque of reduction drive gear (reduction driven gear bearing preload) = Measured starting torque of reduction drive gear as reduction idler gear and driven gear bearing preload - Measured starting torque of reduction drive gear as reduction idler gear preload Tightening torque Corrected starting torque of reduction drive gear (reduction driven gear bearing preload): 0.35 - 2.5 N.m (3.5 - 25 kg-m, 0.25 - 1.8 lb-ft)
6. Apply thread lock cement to thread part of adjuster plate bolts (1). "A": Thread lock cement 99000-32110
7. Install adjuster plates (2) to transfer right and left case so as one side of plate claw to touch dent wall of bevel gear adjuster (3) as shown in figure to prevent bevel gear adjusters (3) from loosing. Tightening torque Adjuster plate bolt a: 12 N.m (1.2 kg-m, 9.0 lb-ft)
8. Inspect tooth contact according to Bevel Gear Tooth Contact Inspection .
9. Apply sealant to one of retainer bolts (1). "A": Sealant 99000-31260
10. Install transfer output retainer assembly (2) with bevel pinion shims (3) to transfer sub-assembly (4) by tightening retainer bolts (1) to specified torque. Tightening torque Transfer output retainer bolt a: 50 N.m (5.0 kg-m, 36.5 lb-ft)
11. Install intermediate shaft bearing (2) to intermediate shaft (3) by using special tool. Special Tool : 09941-74910
12. Install intermediate shaft with bearing in transfer (4).
13. Install new snap ring (1) to transfer right case by using special tool. Special Tool : 09952-76011
14. Apply grease to new intermediate output oil seal lip. "A": Grease 99000-25010
15. Drive intermediate output oil seal (1) in transfer right case (2) by using special tool and hammer. Special Tool 09925-15410 Intermediate output oil seal installing depth "a": 1.0 - 2.0 mm (0.04 - 0.08 in.)

Reduction Drive Gear, Reduction Idler Gear and Reduction Driven Gear Disassembly and Assembly

Reference: TRANSFER DISMOUNTING AND REMOUNTING

Reference: TRANSFER ASSEMBLY COMPONENTS

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND ASSEMBLY

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1. Drive out bearings of reduction drive gear, reduction idler gear and reduction driven gear by using bearing puller (1) and hydraulic press (2).

Assembly

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1. Drive in reduction drive gear bearings (right and left) to reduction drive gear by using bearing puller and hydraulic press.
2. Drive in reduction idler gear bearings (1) (right and left) to reduction idler gear (2) by using special tools and hydraulic press (5). Special Tool 09924-74590 09944-66060
3. Drive in reduction driven gear bearings (3) (right and left) to reduction driven gear (4) by using special tools and hydraulic press (5). Special Tool A 09924-74590 C 09925-68210 Reduction gear taper roller bearings dimension REDUCTION GEAR TAPER ROLLER BEARINGS DIMENSION SPECIFICATION Outside diameter Width Reduction idler gear taper roller bearing 47 mm (1.85 in.) 15 mm (0.59 in.) Reduction driven gear RH taper roller bearing 52 mm (2.05 in.) 16.3 mm (0.64 in.) Reduction driven gear LH taper roller bearing 52 mm (2.05 in.) 19.3 mm (0.76 in.)

Reference: TRANSFER DISMOUNTING AND REMOUNTING

Reference: TRANSFER ASSEMBLY COMPONENTS

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND ASSEMBLY

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1. Remove oil seals (1) from transfer right case and left case by using special tool. Special Tool 09913-50121
2. Remove oil protect plate (2) and oil receiver (3) from transfer right case.
3. Remove adjuster plates (1) from transfer right and left cases.
4. Remove bevel gear adjuster (2) from transfer right and left case by using special tool. Special Tool 09940-14940

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1. Apply grease to reduction drive gear oil seal lips "A": Grease 99000-25010
2. Install reduction drive gear oil seals (1, 2) to right case (3) by using special tool. CAUTION: Use care the installation direction and depth of oil seals for correct installation. Special Tool : 09913-75520 Transfer reduction drive gear oil seal installing depth "a": 13.4 - 14.0 mm (0.528 - 0.551 in.) "b": 3.0 - 3.6 mm (0.118 - 0.141 in.)
3. Fill inside of oil seal (2) with grease of about 3 g (0.11 oz.). "B": Grease 99000-25010
4. Screw bevel gear adjuster (1) in right case (2) until side face of bevel gear adjuster (1) come to flush position with side face of right case (2) by using special tool. Special Tool 09940-14940 NOTE: Do not screw in bevel gear adjuster excessively, or preload of reduction idler gear taper roller bearing may not be adjusted accurately.
5. Install oil protect plate (1) and oil receiver (2) to right case (3). Tightening torque Oil protect plate bolt a: 12 N.m (1.2 kg-m, 9.0 lb-ft) Oil receiver bolt b: 12 N.m (1.2 kg-m, 9.0 lb-ft)
6. Apply grease to reduction drive gear oil seal lips. "A": Grease 99000-25010
7. Install reduction drive gear oil seals (1) to left case (2) by using special tool. CAUTION: Use care of the installation direction and depth of oil seals for correct installation. Special Tool : 09913-85210 Transfer reduction drive gear oil seal installing depth "a": 13.0 - 14.0 mm (0.512 - 0.551 in.) "b": 2.5 - 3.5 mm (0.098 - 0.138 in.)
8. Screw bevel gear adjuster (1) in left case (2) until side face of bevel gear adjuster (1) come to flush position with side face of left case (2) by using special tool. Special Tool 09940-14940 NOTE: Do not screw in bevel gear adjuster excessively, or preload of reduction idler gear taper roller bearing may not be adjusted accurately.

Reference: TRANSFER DISMOUNTING AND REMOUNTING

Reference: TRANSFER ASSEMBLY COMPONENTS

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND ASSEMBLY

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1. Uncaulk transfer output flange nut.
2. Remove transfer output flange nut while holding flange (1) by using special tool. Special Tool 09930-40113
3. Remove transfer output flange (1) by bearing puller (2).
4. Drive out bevel pinion shaft (1) from transfer output retainer by tapping it with plastic hammer (2).
5. Drive out pinion shaft bearing from bevel pinion shaft by using bearing puller and hydraulic press.
6. Remove pinion shaft oil seal (1) by using special tool. Special Tool 09913-50121
7. Remove pinion shaft rear taper roller bearing (1) and spacer (2).
8. Drive out pinion shaft taper roller bearing outer races (2) (front and rear) by using brass bar (1).

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1. To mesh bevel gears correctly, it is required to install bevel pinion to transfer output retainer properly by using adjusting shim (bevel pinion shim) as follows. Install pinion shaft front taper roller bearing (1) to bevel pinion dummy (special tools). Special Tool 09922-76140 09922-76420 Install bevel pinion dummy (1), pinion shaft rear taper roller bearing (2) and special tools to transfer output retainer (3). Special Tool 09922-76140 09922-76420 09922-76310 09922-76320 09922-76340 09922-76150 NOTE: Do not install spacer and oil seal for this adjustment. Tighten bevel pinion nut (special tool) so that specified bearing preload is obtained. NOTE: Before measurement, check for rotation by hand more than 15 revolutions. Tightening torque Rotational torque of bevel pinion shaft (Bearing preload): 0.50 - 1.50 N.m (5.0 - 15.0 kg-m, 0.35 - 1.10 lb-ft) Measure height "b" in figure by using vernier caliper. Calculate "c" by using measured value. Distance "c" = Height "b" - Height "a" 40 mm (1.575 in.) Obtain adjusting shim thickness by the following equation. Necessary shim thickness "f" = Distance "c" + Distance "d" 61.2 mm (2.409 in.) - Distance "e" 79.25 mm (3.120 in.) Select adjusting shim closest to calculated value from among the following available sizes. Available bevel pinion shim thickness 0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81, 0.84 and 0.87 mm (0.012, 0.024, 0.025, 0.026, 0.027, 0.028, 0.030, 0.031, 0.032, 0.033 and 0.034 in.)
2. Press-fit pinion shaft taper roller bearing outer races (front and rear) by using special tools and hydraulic press (1). Special Tool 09913-75821 09924-84510-002 09924-84510-005 09951-18210
3. Press-fit pinion shaft front taper roller bearing by using special tools and hydraulic press. Special Tool 09941-74910 09925-88210
4. Install bevel pinion shaft with new pinion shaft spacer to transfer output retainer.
5. Drive in pinion shaft rear taper roller bearing by using special tool and tapping lightly with plastic hammer (1). Special Tool 09913-75810
6. Apply grease to new oil seal lip. "A": Grease 99000-25010
7. Drive in oil seal (1) by using special tool and hammer. Special Tool 09913-75810 Transfer output flange oil seal installing depth "a": 1.0 - 2.0 mm (0.04 - 0.08 in.)
8. Install transfer output flange (1) by tapping with plastic hammer and tighten transfer output flange nut gradually so as rotational torque of bevel pinion shaft to be in specified value. NOTE: If rotational torque of bevel pinion shaft exceeds specification given in the following, replace pinion shaft spacer and tighten flange nut. Before taking measurement of rotational torque, rotate pinion shaft over ten rounds in advance. Special Tool 09930-40113 Tightening torque Transfer output flange nut (reference): 90 - 150 N.m (9.0 - 15.0 kg-m, 65.0 - 108 lb-ft) Rotational torque of bevel pinion shaft (Bearing preload): 0.5 - 1.50 N.m (0.05 - 0.15 kg-m, 0.35 - 1.10 lb-ft)
9. Caulk transfer output flange nut (1).

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND ASSEMBLY

Reference: TRANSFER DISMOUNTING AND REMOUNTING

1. Check each bearing for smooth rotation, wear or discoloration If found abnormal, replace.
2. Check oil seal for leakage and its lip for excessive hardness If either is found, replace.
3. Check transfer case for cracks.
4. Check bevel pinion and bevel gears for wear or cracks.