Transfer: Other — Suzuki SX4 I (2006-2009)

Transfer: Other Suzuki SX4 I

Transfer Case 8 illustrations ~422 words

Remounting

Reverse dismounting procedure for remounting of transfer, noting the following points.

Scheme 59

Scheme 59: Remounting

Scheme 60

Apply grease to left case (1) and new O-ring (2) as shown in figure.
Use new O-ring.
Apply grease to O-ring (2). "A": Grease 99000-25010SUZUKI Super Grease A
Tighten front suspension bolts to specified torque referring to «FRONT SUSPENSION CONSTRUCTION»(ref-268909-S36651081132007102700000) .
Tighten bolts and nut specified torque as follows. Tightening torque Stiffener No.1 bolt and No.2 bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft) Transfer to transaxle bolt b: 98 N.m (9.8 kg-m, 71.0 lb-ft) Engine rear mounting upper nut c: 25 N.m (2.5 kg-m, 18.0 lb-ft) Engine rear mounting lower nut d: 55 N.m (5.5 kg-m, 40.0 lb-ft)
Pour transaxle oil and transfer oil referring to «MANUAL TRANSAXLE OIL CHANGE»(ref-268911-S34240057862007102700000) or «A/T FLUID CHANGE»(ref-268912-S10487220472007102700000) and «TRANSFER OIL CHANGE»(ref-268913-S23420868992007102700000) .
Refill P/S fluid and bleed air referring to «HYDRAULIC TYPE»(ref-268943-S13043899622007102700000) (Hydraulic P/S model).
Confirm front wheel alignment referring to «FRONT WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT»(ref-268909-S17018294082007102700000) .

Scheme 61

Scheme 61: Transfer Assembly Components

Reference: TRANSFER DISMOUNTING AND REMOUNTING

Reference: TRANSFER ASSEMBLY COMPONENTS

Gear tooth contact table

GEAR TOOTH CONTACT CHART Tooth contact pattern Diagnosis and remedy Normal High contact Pinion is positioned too far from the center of drive bevel gear. Decrease thickness of bevel pinion shim and position pinion closer to gear center. Adjust drive bevel gear backlash to specification. Low contact Pinion is positioned too close to the center of drive bevel gear. Increase thickness of bevel pinion shim and position pinion farther from gear center. Adjust drive bevel gear backlash to specification. These contact patterns indicate that the "offset" of reduction driven gear is too much or too little. The remedy is to change the division of the bevel gear shim(s). These contact patterns, located on toe or heel on both drive and coast sides, mean that 1) both pinion and gear are defective, 2) retainer is not true, or 3) gear is not properly seated on transfer case. The remedy is to replace the defective member. Irregular patterns: If the pattern is not oval, it means that bevel gear is defective. High or low spots on tooth surfaces or on the seat of bevel gear are the cause of irregular patterns appearing on some teeth. The remedy is to replace the pinion and gear set and, if the seat is defective, so is transfer case