Transfer Case: Diagnosis Suzuki Vitara I

Transfer Symptom Diagnosis

Before attempting to repair the transfer or related components for any reason other than mechanical failure, the condition and probable causes should be identified.

Transfer failures are revealed by shifting difficulties such as excessive shifting effort, gear clash, or gear grinding. When any of these conditions occur, the following inspections should be made before disassembling the transfer.

1. Check transfer oil level for insufficient or incorrect oil. See «CHANGING FLUID»(ref-162062-S24075518842004051200000) .
2. Check transfer mountings for wear or looseness.
3. Check gearshift control lever for distortion or excessive wear.

Scheme 1

Scheme 2

Transfer Gear Oil Inspection & Change

See CHANGING FLUID .

Scheme 3

Scheme 4

Scheme 5

1. Lift up vehicle horizontally.
2. Give match marks (1) on joining flange and propeller shaft as shown in the figure.
3. Remove 4 bolts from rear propeller shaft flange and remove propeller shaft.
4. Using flat end rod or the like, remove oil seal.
5. Using special tool and plastic hammer, press fit new (2) seal up to transfer rear case (1) surface. Be sure to apply grease to oil seal lip. "A": Grease 99000-25010 Special tool (A): 09940-53111
6. Clean and inspect sliding portion of propeller shaft front end (where oil seal contacts) before installation and if even small dent or scratch exists, correct and clean it again. Then apply grease inside splines of propeller shaft. "B": Grease 99000-25010
7. Install propeller shaft and torque universal joint flange bolts to specification.

1. Tightening torque
2. Universal joint flange bolt (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Scheme 6