Transfer: Overhaul Suzuki SX4 I рестайлинг

Disassembly

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

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1. Remove right case oil seal No. 1 (1) from transfer right case using special tool. Special Tool : 09913-50121
2. Remove snap ring (2) by using snap ring pliers.
3. Remove intermediate shaft (4) with intermediate shaft bearing (3) from transfer assembly.
4. Remove intermediate shaft bearing (3) from intermediate shaft (4) by using bearing puller and hydraulic press.
5. Remove transfer output retainer assembly (1) and shim (3) by removing retainer bolts (2).
6. Remove transfer case bolts (4).
7. Separate transfer right case (5) from transfer left case (6) by using special tool. Special Tool (A): 09912-34510
8. Remove reduction drive gear assembly (7) and reduction driven gear assembly (9).
9. Remove shim (10) and bearing outer races (8). NOTE: When it is difficult to remove bearing outer races from cases, remove them with special tool. Special Tool (B): 09944-96011

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1. Select appropriate shim as follows. Measure distance "a" between taper roller bearing outer races of reduction driven gear assembly (1). Measure depth "b" of left case (2) and "c" of right case (3). Obtain adjusting shim thickness by the following equation. THICKNESS SPECIFICATIONS Necessary shim thickness = Depth "b" + Depth "c" - Distance "a" + 0.1 mm (0.004 in.) Select a shim which is close to half thickness of the calculated value (necessary shim thickness) from among the available shims to install it between bearing and case at each of right and left sides. For example: Measure distance "a" is 110.75 mm (4.360 in.). Measure depth "b" is 85.8 mm (3.378 in.). Measure depth "c" is 26.55 mm (1.045 in.). Necessary shim thickness = 85.8 mm (3.378 in.) + 26.55 mm (1.045 in.) - 110.75 mm (4.360 in.) + 0.1 mm (0.004 in.) = 1.7 mm (0.067 in.) 1.7 mm (0.067 in.) ÷ 2 = 0.85 mm (0.033 in.) Calculated thickness of new shim = 0.85 mm (0.033 in.) Available reduction driven gear shim thickness 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1.00 and 1.05 mm (0.024, 0.026, 0.028, 0.030, 0.031, 0.033, 0.035, 0.037, 0.039 and 0.041 in.)
2. Clean mating surface of right and left cases, and apply sealant to right case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)
3. Assemble the following parts in right and left cases by reversing disassembling procedure. Reduction drive gear assembly (1) Reduction driven gear assembly (3) Bearing outer races (2) Reduction driven gear shims (5) Dowel pin (6)
4. Tighten transfer case bolts (4) to specified torque. Tightening torque Transfer case bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
5. Select bevel pinion shim (3) referring to step 1 ) of "Reassembly" under «TRANSFER OUTPUT RETAINER ASSEMBLY DISASSEMBLY AND REASSEMBLY»(ref-514591-S33536024002012112100000) .
6. Inspect tooth contact according to «BEVEL GEAR TOOTH CONTACT INSPECTION»(ref-514591-S38601425352012112100000) .
7. Install transfer output retainer assembly (2) with bevel pinion shim (3) to transfer left case (4) by tightening retainer bolt (1) to specified torque. Tightening torque Transfer output retainer bolt (a): 55 N.m (5.5 kg-m, 40.0 lbf-ft)
8. Install bolt to bolt hole of flange (2), set dial gauge measuring tip at right angles to bolt (1) as shown in figure. Holding reduction driven gear by hand, take measurement backlash of pinion and bevel gear. NOTE: If backlash exceeds specification given below, adjust it by changing thickness ratio of shims assembled in right and left cases in Step 3 ). Special Tool 09900-20607 09900-20701 Bevel pinion & bevel gear backlash : 0.1 - 0.2 mm (0.0039 - 0.0078 in.)
9. Install intermediate shaft bearing (1) to intermediate shaft (2) by using special tool. Special Tool (A): 09913-84510
10. Install intermediate shaft (2) with bearing (3) in transfer.
11. Install new snap ring (1) to transfer right case by using snap ring pliers.
12. Apply grease to new right case oil seal No. 1 lip. "A": Grease 99000-25011 (SUZUKI Super Grease A)
13. Drive right case oil seal No. 1 (1) in transfer right case (2) by using special tool and hammer. Special Tool (A): 09925-16010 Intermediate output oil seal installing depth "a": 1.5 - 2.0 mm (0.059 - 0.078 in.)

Reduction Drive Gear Assembly Disassembly and Reassembly

Reference: TRANSFER DISMOUNTING AND REMOUNTING

Reference: TRANSFER ASSEMBLY COMPONENTS

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND REASSEMBLY

Remove bearings (1) from reduction drive gear (2) using special tool, bearing puller (3) and hydraulic press (4).

Special Tool

(A): 09913-85230

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1. Clean all components thoroughly, inspect them for any abnormality and replace with new one as necessary.
2. Install bearings (1) to reduction drive gear (2) using special tool, bearing puller (3) and hydraulic press (4). Special Tool (A): 09913-85230

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1. Remove left bearing (1) and bevel gear (2) using special tool, bearing puller (3) and hydraulic press (4). Special Tool (A): 09925-98221
2. In order to remove right bearing (1) from reduction driven gear (2), grind with a grinder (3) one part "a" of bearing as illustrated till it becomes thin. CAUTION: Be careful not to grind too far not to damage reduction driven gear.
3. Break with a chisel (1) the thin ground bearing (2), and it can be removed.

Reassembly

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1. Install right bearing (1) to reduction driven gear (2) using special tools and hydraulic press. Special Tool 09924-74510 09925-16310
2. Install bevel gear (1) to reduction driven gear (2) using special tools and hydraulic press. Special Tool 09924-07710 09924-84510-005 09925-15410
3. Install left bearing (1) to reduction driven gear (2) using special tools and hydraulic press. Special Tool 09913-84510 09924-84510-005

Reference: TRANSFER DISMOUNTING AND REMOUNTING

Reference: TRANSFER ASSEMBLY COMPONENTS

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND REASSEMBLY

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1. Remove oil seals from right case (1) using special tool, if necessary. Special Tool (A): 09925-15410
2. Remove oil plate (1) from right case (2), if necessary.
3. Remove oil seals from left case using flat end rod or the like, if necessary.

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1. When installing oil seal No. 2 (1) and No. 3 (2) to right case (3) using special tool, use care so that oil seals in proper direction and position as shown in figure. Apply grease to oil seal lip. Special Tool (A): 09925-15410 "A": Grease 99000-25011 (SUZUKI Super Grease A) Oil seals installing depth "a": 23.5 - 24.5 mm (0.925 - 0.964 in.) "b": 38.0 - 39.0 mm (1.496 - 1.535 in.)
2. Install oil plate to right case. Tightening torque Oil plate bolt: 10 N.m (1.0 kg-m, 7.5 lbf-ft)
3. When installing new oil seal No. 1 (1) and No. 2 (2) to left case (3) using special tool, use care so that oil seals in proper direction as shown in figure. Apply grease to oil seal lip. Special Tool (A): 09913-85210 (For oil seal No. 1) (A): 09944-88210 (For oil seal No. 2) "A": Grease 99000-25011 (SUZUKI Super Grease A)

Reference: TRANSFER DISMOUNTING AND REMOUNTING

Reference: TRANSFER ASSEMBLY COMPONENTS

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND REASSEMBLY

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

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1. To mesh bevel gears correctly, it is prerequired to install bevel pinion to transfer output retainer properly by using adjusting shim (bevel pinion shim) as follows. Install front taper roller bearing (1) to bevel pinion dummy (special tools). Special Tool 09922-76140 09922-76430 Install bevel pinion dummy (1), rear taper roller bearing (2) and special tools to transfer output retainer (3). Special Tool 09922-76140 09922-76420 09922-76340 09922-76150 NOTE: This installation requires no spacer or oil seal. Tighten bevel pinion nut (special tool) so that specified bearing preload is obtained. NOTE: Before taking measurement, check for rotation by hand more than 15 revolutions. Rotational torque of bevel pinion (Bearing preload) 0.50 - 1.30 N.m (0.05 - 0.13 kgf-m, 0.35 - 0.95 lbf-ft) Measure height "b" in figure by using vernier caliper. Calculate "c" by using measured value. HEIGHT SPECIFICATIONS Distance "c" = Height "b" - Height "a" 40 mm (1.575 in.) Obtain adjusting shim thickness by the following equation. SHIM THICKNESS SPECIFICATIONS Necessary shim thickness "f" = Distance "c" + Distance "d" - Distance "e" 74.0 mm (2.913 in.) 101.95 mm (4.014 in.) Select a shim closest to the calculated value (necessary shim thickness) from among the available shims or combine shims to become closest to calculated value. For example: Measure distance "b" is 69.95 mm (2.754 in.). "c" = 69.95 mm (2.754 in.) - 40.0 mm (1.757 in.) = 29.95 mm (1.179 in.) "f" = 29.95 mm (1.179 in.) + 74.0 mm (2.913 in.) - 101.95 mm (4.014 in.) = 2.0 mm (0.079 in.) Calculated thickness of new shim = 2.0 mm (0.079 in.) Available bevel pinion shim thickness 0.30, 1.85, 1.88, 1.91, 1.94, 1.97, 2.00, 2.03, 2.06, 2.09, 2.12 and 2.15 mm (0.012, 0.072, 0.074, 0.075, 0.076, 0.077, 0.078, 0.079, 0.081, 0.082, 0.083 and 0.084 in.)
2. Press-fit outer races (front and rear) by using special tool and hydraulic press. Special Tool (A): 09913-75520
3. Press-fit front taper roller bearing (1) by using special tool and hydraulic press. Special Tool (A): 09925-18011
4. Install bevel pinion with new pinion shaft spacer (1) and new pump seal (2) to transfer output retainer (3).
5. Drive in rear taper roller bearing by using special tool and tapping lightly with plastic hammer. Special Tool (A): 09913-84510
6. Apply grease to new oil seal lip. "A": Grease 99000-25011 (SUZUKI Super Grease A)
7. Drive in oil seal (1) by using special tools and hammer. Special Tool 09940-54910 09913-76010 Transfer output flange oil seal installing depth "a": 21.0 - 22.0 mm (0.82 - 0.86 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 to be in specified value. NOTE: If rotational torque of bevel pinion exceeds specification given in the following, replace pinion shaft spacer and tighten flange nut. Before taking measurement of rotational torque, rotate pinion over ten rounds in advance. Bevel pinion bearing preload : 0.5 - 1.3 N.m (0.05 - 0.13 kgf-m, 0.35 - 0.95 lbf-ft) Special Tool (A): 09930-40113

Reference: TRANSFER ASSEMBLY DISASSEMBLY AND REASSEMBLY

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.