Transfer: Removal & Installation Suzuki Equator I

INSTALLATION

Installation is in the reverse order of removal.

1. When installing the transfer control unit, tighten bolts to the specified torque. Transfer control unit bolts: 3.4 N.m (0.35 kg-m, 30 in-lb)
2. After the installation, check 4WD shift indicator pattern. If NG, adjust position between transfer assembly and transfer control unit. Refer to [ «PRECAUTION FOR TRANSFER ASSEMBLY AND TRANSFER CONTROL UNIT REPLACEMENT»(ref-375706-S22400610282010102800000) ].

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1. Partially drain the transfer fluid. Refer to [ «TRANSFER FLUID: REPLACEMENT»(ref-375706-S13165398912010102800000) ].
2. Remove the front propeller shaft. Refer to [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S18478494622010102800000) ]
3. Remove the companion flange self-lock nut using Tool. Tool number: KV40104000 ( - )
4. Put a matching mark on top of the front drive shaft in line with the mark on the companion flange. CAUTION: Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft.
5. Remove the companion flange using suitable tool.
6. Remove the front oil seal from the front case using Tool. Tool number: ST33290001 (J-34286) CAUTION: Do not damage front case.

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1. 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.
2. Align the matching mark of the front drive shaft with the matching mark of the companion flange, then install the companion flange.
3. Install the new self-lock nut and 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.
4. Install the front propeller shaft. Refer to [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S18478494622010102800000) ]
5. Refill the transfer with fluid and check for fluid leakage and fluid level. Refer to [ «TRANSFER FLUID: INSPECTION»(ref-375706-S10229728622010102800000) ].

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1. Partially drain the transfer fluid. Refer to [ «TRANSFER FLUID: REPLACEMENT»(ref-375706-S13165398912010102800000) ].
2. Remove the rear propeller shaft. Refer to [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S18478494622010102800000) ]
3. Remove the dust cover from the rear case. CAUTION: Do not damage the rear case.
4. Remove the rear oil seal from the rear case using Tool. CAUTION: Do not damage the rear case. Tool number: ST33290001 (J-34286)

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1. 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.
2. Install the oil cover until it reaches the end face of the new dust cover. CAUTION: Position the oil cover with the notch at bottom position.
3. 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. 1: Dust cover A: Protrusions 2: Rear case assembly
4. 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.
5. Install the rear propeller shaft. Refer to [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S18478494622010102800000) ]
6. Refill the transfer with fluid and check for fluid leakage and fluid level. Refer to [ «TRANSFER FLUID: INSPECTION»(ref-375706-S10229728622010102800000) ].

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1. Switch the 4WD shift switch to 2WD and set the transfer assembly to 2WD.
2. Disconnect the transfer control device connector.
3. Remove the breather hose from the transfer control device.
4. Remove the bolts and detach the transfer control device.

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1. Install the new O-ring to the transfer control device. CAUTION: Do not reuse O-ring. Apply petroleum jelly to O-ring.
2. Install the transfer control device. 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. 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) ].
3. Install the breather hose to the transfer control device.
4. Connect the transfer control device connector.
5. After the installation, check the 4WD shift indicator pattern. If NG, adjust the position between the transfer assembly and transfer control unit. Refer to [ «PRECAUTION FOR TRANSFER ASSEMBLY AND TRANSFER CONTROL UNIT REPLACEMENT»(ref-375706-S22400610282010102800000) ].

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1. Remove the snap ring.
2. Remove the sun gear assembly from the planetary carrier assembly using suitable tool.
3. Remove the snap ring from the sun gear assembly using suitable tool.
4. Remove the carrier bearing from the sun gear using Tools. Tool number A: ST35300000 ( - ) B: ST30021000 (J-22912-01)
5. Remove the needle bearing from the sun gear using Tool. Tool number: ST33710000 ( - )
6. Remove the metal bushing from the sun gear using Tools. Tool number A: ST33710000 ( - ) B: ST35325000 ( - ) C: ST33290001 (J-34286)

REMOVAL

1. Switch 4WD shift switch to 2WD and set transfer assembly to 2WD.
2. Remove the undercovers using power tool.
3. Drain the transfer fluid. Refer to .
4. Remove the center exhaust tube and main muffler. Refer to [ «EXHAUST SYSTEM: REMOVAL AND INSTALLATION»(ref-375741-S13844705652010102800000) ]
5. Remove the front and rear propeller shafts. Refer to [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S18478494622010102800000) ] (front), [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S12574957202010102800000) ] (rear). CAUTION: Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft. NOTE: Insert a plug into the rear oil seal after removing the rear propeller shaft.
6. Remove the A/T nuts from the A/T crossmember. Refer to [ «TRANSMISSION ASSEMBLY: COMPONENT»(ref-375705-S19453451932010102800000) ]
7. Position two suitable jacks under the A/T and transfer assembly.
8. Remove the A/T crossmember. Refer to [ «TRANSMISSION ASSEMBLY: COMPONENT»(ref-375705-S19453451932010102800000) ] WARNING: Support A/T and transfer assembly using two suitable jacks while removing A/T crossmember.
9. Disconnect the electrical connectors from the following: ATP switch 4LO switch Wait detection switch Transfer control device
10. Disconnect each air breather hose from the following. Refer to [ «AIR BREATHER HOSE: REMOVAL AND INSTALLATION FOR QR25DE ENGINE»(ref-375705-S07361166252010102800000) ] Transfer control device Breather tube (transfer)
11. Remove the transfer to A/T and A/T to transfer bolts.
12. Remove the transfer assembly. WARNING: support transfer assembly with suitable jack while removing it. CAUTION: Do not damage rear oil seal (A/T).

Installation is in the reverse order of removal.

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1. Tighten the bolts to specification. Tightening torque: 36 N.m (3.7kg-m, 27 ft-lb)
2. Fill the transfer with new fluid and check for fluid leakage and fluid level. Refer to [ «TRANSFER FLUID: INSPECTION»(ref-375706-S10229728622010102800000) ].
3. Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to [ «TRANSFER FLUID: INSPECTION»(ref-375706-S10229728622010102800000) ].
4. After the installation, check the 4WD shift indicator pattern. If NG, adjust the position between the transfer assembly and transfer control unit. Refer to [ «PRECAUTION FOR TRANSFER ASSEMBLY AND TRANSFER CONTROL UNIT REPLACEMENT»(ref-375706-S22400610282010102800000) ].

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1. Remove the drain plug and filler plug.
2. Remove the transfer control device from the rear case.
3. Remove the O-ring from the transfer control device.
4. Remove the self-lock nut from the companion flange using Tool. Tool number: KV40104000 ( - )
5. Put a matching mark on top of the front drive shaft in line with the mark on the companion flange. CAUTION: Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft.
6. Remove the companion flange using suitable tool.
7. Remove the front oil seal from the front case using Tool. Tool number: ST33290001 (J-34286) CAUTION: Do not damage front case or front drive shaft.
8. Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from the front case.
9. Remove the wait detection switch (gray) from the rear case.
10. Remove the dust cover from the rear case using suitable tool. CAUTION: Do not damage rear case.
11. Remove the rear oil seal from the rear case using Tool. Tool number: ST33290001 (J-34286) CAUTION: Do not damage rear case or mainshaft.
12. Remove the input oil seal from the front case using suitable tool. CAUTION: Do not damage front case, sun gear or input bearing.
13. Remove the retainer bolts and gaskets.
14. Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.
15. Separate the front case from the rear case. Then remove the rear case by prying it up using suitable tool. CAUTION: Do not damage the mating surface.
16. Remove the spacer from the control shift rod. CAUTION: Do not drop spacer.
17. Remove the snap ring from the mainshaft using suitable tool.
18. Remove the mainshaft rear bearing from the mainshaft using suitable tool.
19. Remove the retainer from the mainshaft.
20. Remove the snap ring from the mainshaft using suitable tool.
21. Remove the oil pump assembly from the mainshaft.
22. Remove the snap ring from the mainshaft using suitable tool.
23. Remove the clutch gear from the mainshaft.
24. Remove the snap ring from the L-H shift rod assembly using suitable tool.
25. Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.
26. Remove the drive chain together with the sprocket and front drive shaft from the front case.
27. Remove the mainshaft from the sun gear assembly.
28. Remove the L-H shift rod assembly and control shift rod assembly from the front case.
29. Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.
30. Remove the snap ring from the sun gear. CAUTION: Do not damage sun gear or input bearing.
31. Press the sun gear assembly and planetary carrier assembly from the front case using Tool. Tool number: KV38100200 ( - )
32. Remove the snap ring from the front case.
33. Remove the internal gear from the front case.
34. Remove the snap ring from the front case.
35. Remove the input bearing from the front case using Tool. Tool number: KV38100200 ( - )
36. Remove the baffle plate from the front case.
37. Remove the breather tube from the front case.