Transfer: Other Suzuki Equator I

Pattern A

1. Shift the transmission according to the directions below, and stay in "N" for at least 2 seconds. For A/T models, stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. For M/T models, stop vehicle and move M/T shift lever to the neutral position with brake and clutch pedal depressed.
2. Turn 4WD shift switch to "4LO" position. Stay in "4LO" for at least 2 seconds.
3. Turn ignition switch "OFF".
4. Start engine.
5. Erase self-diagnosis. Refer to [ «SDT FUNCTION (4WD)»(ref-375706-S19974404892010102800000) ].
6. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to " «CHECK 4WD SHIFT INDICATOR PATTERN»(ref-375706-S42559178422010102800000) ". If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer control unit and retry the above check.

Pattern B

1. Shift the transmission according to the directions below, and stay in "N" for at least 2 seconds. For A/T models, stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. For M/T models, stop vehicle and move M/T shift lever to the neutral position with brake and clutch pedal depressed.
2. Turn ignition switch "OFF".
3. Start engine.
4. Erase self-diagnosis. Refer to [ «SDT FUNCTION (4WD)»(ref-375706-S19974404892010102800000) ].
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to " «CHECK 4WD SHIFT INDICATOR PATTERN»(ref-375706-S42559178422010102800000) ". If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer control unit and retry the above check.

Service Notice

1. After overhaul refill the transfer with new transfer fluid.
2. Check the fluid level or replace the fluid only with the vehicle parked on level ground.
3. During removal or installation, keep inside of transfer clear of dust or dirt.
4. Disassembly should be done in a clean work area.
5. Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
6. Check for the correct installation status prior to removal or disassembly. If matchmarks are required, be certain they do not interfere with the function of the parts when applied.
7. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly.
8. Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them with a new ones if necessary.
9. Gaskets, seals and O-rings should replaced any time the transfer is disassembled.
10. In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, use it.
11. Observe the specified torque when assembling.
12. Clean and flush the parts sufficiently and blow-dry them.
13. Be careful not to damage sliding surfaces and mating surfaces.
14. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transfer.

Integrates actuator motor and actuator position switch.

Actuator Motor

Moves shift rods when signaled by transfer control unit.

Actuator Position Switch

Detects actuator motor position and then sends signal to transfer control unit.

WAIT DETECTION SWITCH

Detects if transfer case is in 4WD by the 2-4 shift fork position.

Note. If 4WD shift switch is switched to 4H or 4LO and the transfer case is not in 4WD completely, the wait detection system will operate.

4LO SWITCH

4LO switch detects if the transfer case is in 4LO by the position of the L-H shift fork.

ATP SWITCH (A/T MODELS)

ATP switch detects if transfer case is in neutral by the position of the L-H shift fork.

Note. Transfer case may be in neutral when shifting between 4H-4LO.

PNP SWITCH (M/T models)

PNP switch detects if manual transmission is under neutral condition.

1. Transfer control unit controls transfer control device and it directs shifts from 4H-4LO and 2WD-4WD.
2. Self-diagnosis can be done.

Transfer shift high and low relays apply power supply to transfer control device (actuator motor).

Transfer shut off relays 1 and 2 apply power supply to transfer control unit.

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4WD Shift Switch

4WD shift switch is able to select from 2WD, 4H or 4LO.

4WD Shift Indicator Lamp

1. Displays driving conditions selected by the 4WD shift switch while engine is running. When the 4WD warning lamp is turned on, all 4WD shift indicator lamps will turn off.
2. Turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1 second after the engine starts if system is normal.

4LO Indicator Lamp

1. Displays 4LO while engine is running. 4LO indicator lamp flashes if transfer gear does not shift completely into 4H4LO. In this condition, the transfer case may be in neutral and the A/T parking mechanism may not operate.
2. Turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1 second after the engine starts if system is normal.

4WD WARNING LAMP

Turns on or flashes when there is a malfunction in 4WD system.

Also turns on when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1 second after the engine starts if system is normal.

4WD Warning Lamp Indication

4WD WARNING LAMP INDICATION CHART

ATP WARNING LAMP (A/T MODELS)

When the A/T selector lever is in "P" position, the vehicle may move if the transfer case is in neutral. ATP warning lamp is turned on to indicate this condition to the driver.

4WD System: CAN Communication

Refer to [ CAN COMMUNICATION SYSTEM: SYSTEM DESCRIPTION ]

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DETAILED FLOW

DIAGNOSIS PROCEDURE

Function

SDT can display each diagnostic item using the diagnostic test modes shown following.

4WD DIAGNOSTIC MODE CHART

Display Item List

DISPLAY ITEM LIST

SDT Data list item

SDT DATA LIST ITEM

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TERMINAL SPECIFICATIONS

Note. Data are reference value and are measured between each terminal and ground.

FLASH CODE CHART

FLASH CODE CHART

Note. If actuator position switch" or transfer control device" is displayed, first erase DTC. (They may be displayed after installing transfer control unit or transfer assembly.)

Bearing

Check the bearing for damage and rough rotation. If necessary, replace the bearing with a new one.

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1. Measure the end play of each pinion gear. If it is out of specification, replace the planetary carrier assembly with new one. Pinion gear end play: 0.1 - 0.7 mm (0.004 - 0.028 in)
2. Check the working face of each gear and bearing for damage, burrs, partial wear, dents and other abnormality. If any is found, replace the planetary carrier assembly with a new one.

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1. Check if the oil passage of the sun gear assembly is clogged. For this, try to pass a 3.6 mm (0.142 in) dia. wire through the oil passage as shown.
2. Check the sliding and contact surface of each gear and bearing for damage, burrs, partial wear, dents and other abnormality. If any is found, replace the sun gear assembly with a new one.

Internal Gear

Check the internal gear teeth for damage, partial wear, dents or other abnormality. If any is found, replace the internal gear with a new one.

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1. Apply ATF to the new metal bushing, then install the new metal bushing until it becomes "Dimension A" using Tool. Tool number: ST35300000 ( - ) Dimension A: 7.7 - 8.3mm (0.303 - 0.327in) CAUTION: Do not reuse metal bushing.
2. Apply ATF to the new needle bearing, then install the new needle bearing until it becomes "Dimension B" using Tool. Tool number: ST33220000 ( - ) Dimension B: 62.5 - 63.1mm (2.461 - 2.484in) CAUTION: Do not reuse needle bearing.
3. Install the carrier bearing to the sun gear using Tools. Tool number A: ST30720000 (J-25405) B: ST27863000 ( - )
4. Install the new snap ring to the sun gear assembly using suitable tool. CAUTION: Do not reuse snap ring.
5. Install the sun gear assembly to the planetary carrier assembly.
6. Install the new snap ring to the planetary carrier assembly. CAUTION: Do not reuse snap ring.

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1. Remove the front bearing using Tools. Tool number A: ST35300000 ( - ) B: ST30021000 (J-22912-01)
2. Remove the rear bearing using Tools. Tool number A: ST33710000 ( - ) B: ST30021000 (J-22912-01)

Front Drive Shaft

Check the items below. If necessary, replace them with new ones.

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1. Damage, peeling, dent, uneven wear and bending of the shaft.
2. Excessive wear, damage and peeling of the gear.

Check the bearing for damage and rough rotation. If necessary, replace the bearing with a new one.

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1. Install the rear bearing using Tools. Tool number A: KV38100500 ( - ) B: ST30901000 (J-26010-01)
2. Install the front bearing using Tools. Tool number A: KV38100500 ( - ) B: ST30901000 (J-26010-01)

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1. Remove the snap ring.
2. Remove the retaining pin.
3. Remove the drum cam from the control shift rod.
4. Remove the retaining pin from the L-H shift rod.
5. Remove the 2-4 shift bracket.
6. Remove the retaining ring from the 2-4 shift fork using suitable tool.
7. Remove the fork guide collar and 2-4 shift fork spring from the 2-4 shift fork.

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1. Measure the clearance between the shift fork and sleeve. If it is out of specification, replace it with a new one. Standard value 2-4: Less than 0.46 mm (0.018 in) L-H: Less than 0.46 mm (0.018 in)

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1. Check the working face of the shift rod and fork for wear, partial wear, abrasion, bending and other abnormality. If any is found, replace with a new one.

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1. Install clevis pin and shift collar to L-H shift fork after assembling them. CAUTION: Use caution when installing L-H shift fork, clevis pin or shift collar.
2. Install clevis pin and shift collar to 2-4 shift bracket after assembling them. CAUTION: Use caution when installing 2-4 shift bracket.
3. Install guide fork collar and 2-4 shift fork spring to the 2-4 shift fork, and then secure it with the new retaining ring. CAUTION: Do not reuse retaining ring. Be careful with orientation.
4. Install the 2-4shift bracket to the L-H shift rod.
5. Install the new retaining pin evenly to the L-H shift rod. CAUTION: Do not reuse retaining pin.
6. Install the drum cam to the control shift rod, and then secure it with the new retaining pin. CAUTION: Do not reuse retaining pin.
7. Install the new snap ring to the control shift rod. CAUTION: Do not reuse snap ring.

Case

Check the contact surfaces of the shift rod and bearing for wear and damage. If any is found, replace with a new one.

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Sleeve

Check the items below. If necessary, replace them with new ones.

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1. Damage and excessive wear of the contact surfaces of the sprocket, mainshaft and sleeve.
2. Sleeve must move smoothly.

Gear, Shaft and Drive Chain

Check the items below. If necessary, replace them with new ones.

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1. Damage, peeling, uneven wear and bending of the shaft.
2. Excessive wear, damage and peeling of the gear.

Check the bearing for damage and rough rotation. If necessary, replace it with a new one.

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1. Install the breather tube. CAUTION: Install breather tube in the direction shown.
2. Install the baffle plate to the front case. Tighten the bolt to the specified torque. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ]. CAUTION: Install baffle plate by pushing it in the direction shown while tightening the bolt.
3. Install the input bearing to the front case using Tool. Tool number: ST30720000 (J-25405)
4. Install the new snap ring to the front case. CAUTION: Do not reuse snap ring.
5. Install the internal gear with the groove facing up into the front case.
6. Install the new snap ring to the front case. CAUTION: Do not reuse snap ring.
7. Install the planetary carrier assembly and sun gear assembly to the front case using Tool. Tool number: KV38100200 ( - )
8. Install the new snap ring to the sun gear. CAUTION: Do not reuse snap ring. Do not damage sun gear.
9. Set the L-H sleeve together with the L-H shift fork assembly onto the planetary carrier assembly.
10. Install the control shift rod assembly to the front case. CAUTION: Set pin of L-H shift fork assembly into the groove of drum cam.
11. Turn the control shift rod assembly fully counterclockwise.
12. Install the L-H shift rod assembly through the L-H shift fork assembly opening to the front case. CAUTION: Set pin of L-H shift rod assembly into the groove of drum cam.
13. Install the mainshaft to the sun gear assembly.
14. Install the drive chain to the front drive shaft and sprocket. CAUTION: Install with the identification mark of drive chain on the side of the rear bearing of front drive shaft.
15. Install the drive chain together with the front drive shaft and sprocket to the front case.
16. Install the 2-4 sleeve and 2-4 shift fork assembly to the mainshaft. CAUTION: Install with proper orientation of 2-4 sleeve. Install 2-4 shift fork with engaging the grooves of 2-4 shift fork in the retaining pin of 2-4 shift bracket.
17. Install the new snap ring to the L-H shift rod assembly using suitable tool. CAUTION: Do not reuse snap ring.
18. Install the clutch gear to the mainshaft.
19. Install the new snap ring to the mainshaft using suitable tool. CAUTION: Do not reuse snap ring.
20. Install the oil pump assembly to the mainshaft.
21. Install the new snap ring to the mainshaft using suitable tool. CAUTION: Do not reuse snap ring.
22. Install the retainer to the mainshaft. CAUTION: Set the projection of oil pump assembly to the identification hole, and then align locating hole of retainer to the L-H shift rod assembly.
23. Install the mainshaft rear bearing to the mainshaft using Tool. Tool number: KV32102700 ( - ) CAUTION: Do not push too hard in order to avoid snap rings becoming dislodged from mainshaft.
24. Install the new snap ring to the mainshaft using suitable tool. CAUTION: Do not reuse snap ring.
25. Install the spacer to the control shift rod.
26. Apply liquid gasket to the mating surface of the front case. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ]. CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
27. Install the rear case to the front case.
28. Tighten the bolts to the specified torque. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ]. CAUTION: Be sure to install the harness brackets and air breather hose clamp.
29. Install the retainer bolts with new gaskets. Tighten the bolts to the specified torque. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ]. CAUTION: Do not reuse gasket. Tighten them to the specified torque again.
30. Apply petroleum jelly to the circumference of the new oil seal, and install it to the front case using Tools. Tool number A: ST30720000 (J-25405) B: KV40104830 ( - ) Dimension A: 4.0 - 4.6 mm (0.157 - 0.181 in) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal.
31. Install the new rear oil seal until it is flush with the end face of the rear case using Tool. Tool number: KV38100500 ( - ) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal.
32. Apply petroleum jelly to the circumference of the new dust cover. Position the new dust cover using the identification mark as shown. CAUTION: Do not reuse dust cover. Position the identification mark at the position shown.
33. Install the new dust cover to the rear case using Tool. Tool number: KV40105310 ( - ) CAUTION: Do not reuse dust cover. Apply petroleum jelly to dust cover.
34. Apply sealant to the threads of the wait detection switch (gray). Then install it to the rear case and tighten to the specified torque. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ]. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ]. CAUTION: Remove old sealant and oil adhering to threads.
35. Apply sealant to the threads of the 4LO switch (gray with green paint) and ATP switch (black). Then install them to the front case and tighten to the specified torque. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ]. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ]. CAUTION: Remove old sealant and oil adhering to threads.
36. Install the new front oil seal until it is flush with the end face of the front case using Tool. Tool number: KV38100500 ( - ) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal.
37. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
38. Install the new companion flange self-lock nut. Tighten to the specified torque using Tool. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ]. Tool number: KV40104000 ( - ) CAUTION: Do not reuse self-lock nut.
39. Install the new O-ring to the transfer control device. CAUTION: Do not reuse O-ring. Apply petroleum jelly to O-ring.
40. Install the transfer control device to the rear case. Turn the control shift rod fully counterclockwise using a flat-bladed screwdriver, and then put a mark on the control shift rod. Align the transfer control device shaft cutout with the mark on the control shift rod, and install it. NOTE: Turn the transfer control device when the transfer control device connection does not match. Tighten the bolts to the specified torque. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ].
41. Install the drain plug and filler plug with new gaskets to the rear case. Tighten to the specified torque. Refer to [ «TRANSFER ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375706-S12416830612010102800000) ]. CAUTION: Do not reuse gaskets.

PINION GEAR END PLAY

PINION GEAR END PLAY CHART

CLEARANCE BETWEEN SHIFT FORK AND SLEEVE

CLEARANCE CHART

Special Service Tool

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

SPECIAL TOOLS CHART Tool number (Kent-Moore No.) Tool name Description KV40104000 ( - ) Flange wrench Removing self-lock nut Installing self-lock nut 85 mm (3.35 in) 65 mm (2.56 in) ST33290001 (J-34286) Puller Removing front oil seal Removing rear oil seal Removing metal bushing KV38100500 ( - ) Drift Installing front oil seal Installing rear oil seal Installing rear bearing Installing front bearing 80 mm (3.15 in) dia. 60 mm (2.36 in) dia. KV40105310 ( - ) Drift Installing dust cover 89 mm (3.50 in) dia. 80.7 mm (3.17 in) dia. KV38100200 ( - ) Drift Removing sun gear assembly and planetary carrier assembly Removing input bearing Installing sun gear assembly and planetary carrier assembly 65 mm (2.56 in) dia. 49 mm (1.93 in) dia. ST30720000 (J-25405) Drift Installing input bearing Installing input oil seal Installing carrier bearing 77 mm (3.03 in) dia. 55 mm (2.17 in) dia. KV32102700 ( - ) Drift Installing mainshaft rear bearing 48 mm (1.89 in) dia. 41 mm (1.61 in) dia. KV40104830 ( - ) Drift Installing input oil seal 70 mm (2.76 in) dia. 63.5 mm (2.50 in) dia. ST35300000 ( - ) Drift Removing carrier bearing Installing metal bushing Removing front bearing 59 mm (2.32 in) dia. 45 mm (1.77 in) dia. ST30021000 (J-22912-01) Puller Removing carrier bearing Removing front bearing Removing rear bearing ST33710000 ( - ) Drift Removing needle bearing Removing metal bushing Removing rear bearing 89 mm (3.5 in) 30 mm (1.18 in) dia. 24 mm (0.94 in) dia. ST35325000 ( - ) Drift bar Removing metal bushing 215 mm (8.46 in) 25 mm (0.98 in) dia. M12 x 1.5P ST33220000 ( - ) Drift Installing needle bearing 37 mm (1.46 in) dia. 31 mm (1.22 in) dia. 22 mm (0.87 in) dia. ST27863000 ( - ) Drift Installing carrier bearing 75 mm (2.95 in) dia. 62 mm (2.44 in) dia. ST30901000 (J-26010-01) Drift Installing rear bearing Installing front bearing 79 mm (3.11 in) dia. 45 mm (1.77 in) dia. 35.2 mm (1.38 in) dia

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Commercial Service Tool

COMMERCIAL SERVICE TOOL CHART Tool name Description Puller Removing companion flange Removing mainshaft rear bearing Puller Removing mainshaft rear bearing Pin punch Removing retaining pin 6 mm (0.24 in) dia. Power tool Loosening bolts and nuts

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