Transfer: Overview Suzuki Aerio I

The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction drive gear, reduction idler gear, reduction driven gear and bevel gear of transfer. As bevel gears, which change the direction of driving torque axis to the direction of the angle with 90 degrees, hypoid gears are provided. Hypoid gears have an advantage of preventing gear noise, at the same time, they require accurate adjustment of tooth contact and backlash.

Scheme 1

TRANSFER DIAGNOSIS CHART

Scheme 2

Scheme 3

1. Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
2. With vehicle lifted up, check oil level and leakage. If leakage exists, correct or repair it.
3. Drain old oil, tighten drain plug (2) after applying sealant to its thread and pour new specified oil as shown follows by specified amount (roughly up to level hole). "A": Sealant 99000-31260 Tightening torque Transfer oil drain plug (a): 23 N.m (2.3 kg-m, 17.0 lb-ft) NOTE: It is highly recommended to use SAE 75W-90 Gear oil API GL-4. Whenever vehicle is hoisted for any other service work than oil change, also check for oil leakage.
4. Torque level / filler plug (3) as specified in the following after applying sealant to its thread. "A": Sealant 99000-31260 Tightening torque Transfer oil level / filler plug (b): 23 N.m (2.3 kg-m, 17.0 lb-ft) Transfer gear oil Gear oil API GL-4 . Oil Capacity 0.75 liters (1.60/1.32 US/lmp. pt.)

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. Disconnect negative cable at battery.
2. Remove transfer breather hose from clamp on intake manifold.
3. Remove exhaust cover and exhaust No.1 pipe nuts.
4. Disconnect HO2S coupler.
5. Support engine using engine hanger.
6. Hoist vehicle and remove front wheels.
7. Drain transfer oil and automatic transaxle fluid.
8. Remove ball stud bolts (both RH and LH) by removing ball stud lock nuts (1).
9. Disconnect ball studs of front suspension arms (2) (both RH and LH) from steering knuckles (3).
10. Remove stabilizer joint.
11. Remove engine rear mounting nuts (4).
12. Remove exhaust No.2 pipe hanger bush from suspension frame (5).
13. Remove engine front mounting nuts (12) and mounting member to body bolts (13).
14. Support suspension frame (5) by transmission jack or the like to prevent suspension frame from drop down.
15. Remove 6 suspension frame bolts (6) (both RH and LH).
16. Lift down suspension frame with suspension arms and stabilizer.
17. Separate propeller shaft front end from transfer output flange.
18. Remove exhaust No.1 pipe stay (14).
19. Remove exhaust No.1 pipe (8).
20. Remove exhaust No.2 pipe (10).
21. Remove right side drive shaft . See «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-251075-S13290362612007032000000) .
22. Remove transfer to transaxle stiffener (1) by removing its 4 bolts (2).
23. Remove transfer to engine stiffener (1) by removing its 6 bolts.
24. Support transfer assembly with transmission jack.
25. Remove transfer mounting bolts (1).
26. Separate transfer assembly (1) from transaxle (2).
27. Remove mounting (1) and breather hose (2) from transfer assembly.