Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 46
3C-79 Transfer: Non-Shift Type (Transfer without Shift Actuator)
2) Install input gear assembly (1) to front case (2).
3) Tighten new input gear plate bolts (1) to specified
torque.
Tightening torque
Input gear plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
4) Install needle bearing (1) to rear case (2) using
special tool as shown in figure.
Distance between case and needle bearing “a”
: 0 – 0.5 mm (0 – 0.008 in.)
Special tool
(A): 09913–76010
5) Install new rear oil seal (1) to rear case (2) using
special tool as shown in figure, and then apply
grease to oil seal lip.
Distance between case and oil seal “a”
: 3.5 – 4.5 mm (0.138 – 0.177 in.)
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Special tool
(A): 09913–70123
6) Install rear output shaft assembly (2) to rear case (3),
and then install snap ring (1).
7) Install front drive sprocket (1), front output shaft
assembly (2), drive chain (3) and needle bearing (4)
into rear case.
8) Install front drive sprocket bush (1) into front drive
sprocket (2).
1
2
I5JB0A331092-01
1, (a)
I5JB0A331093-03
(A)
1
2
“a”
I5JB0A331036-02
(A)
1, “A”
2
“a”
I5JB0A331094-04
1
2
3
I5JB0A331025-01
1
2
3
5
4
I5JB0A331024-01
1
2
I5JB0A331039-01
Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-80
9) Install differential lock clutch sleeve (1) to rear
output shaft (2) as shown in figure.
10) Install thrust needle bearing (4), front drive shaft (2)
and needle bearings (1) to rear output shaft (3).
11) Install center differential assembly (1) to rear output
shaft (2).
12) Install reduction shift sleeve (1) to rear output shaft
(2).
13) Select shim (1) as follows.
a) Install shim, washer (2) and used snap ring (3)
into rear output shaft (4).
b) Check clearance between shim and washer.
c) If clearance is out of specified value, select shim
from the following table so that clearance
becomes specified value.
Clearance between shim and washer
: 0.1 – 0.3 mm (0.004 – 0.012 in.)
Available shim thickness
14) Remove used snap ring, and then install new snap
ring (2) and needle bearing (1) to rear output shaft
(3).
15) Install needle bearing (1) to center case (2) using
special tool as shown in figure.
Distance between case and needle bearing “a”
: 0 – 0.5 mm (0 – 0.008 in.)
Special tool
(A): 09913–76010
[A]: Rear case side
1
2
I5JB0A331040-01
1
1
2
3
4
I5JB0A331041-02
1
2
[A]
I5JB0A331095-02
1
2
I5JB0A331096-01
0.4 mm (0.016 in.)
1.6 mm (0.063 in.)
0.6 mm (0.024 in.)
1.8 mm (0.071 in.)
0.8 mm (0.031 in.)
2.0 mm (0.079 in.)
1.0 mm (0.039 in.)
2.2 mm (0.087 in.)
1.2 mm (0.047 in.)
2.4 mm (0.098 in.)
1.4 mm (0.055 in.)
1
3
4
2
I5JB0A331097-01
1
2
3
I5JB0A331098-02
1
(A)
2
“a”
I5JB0A331099-02
3C-81 Transfer: Non-Shift Type (Transfer without Shift Actuator)
16) Install oil pipe (1) and knock pin (2) into center case
(3).
17) Install front oil seal No.1 (4) into center case using
special tool as shown in figure, and then apply
grease to oil seal lip.
Distance between case and oil seal “a”
: 3.5 – 4.5 mm (0.138 – 0.177 in.)
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Special tool
(A): 09913–70123
18) Clean mating surface of both center case and rear
case (1), apply sealant to rear case as shown in
figure by such amount that its section is 1.2 mm
(0.047 in.) in diameter, mate center case with rear
case and then tighten bolts (2) to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Rear case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
19) Clean mating surface of both center case (1) and
front case, apply sealant to center case as shown in
figure by such amount that its section is 1.2 mm
(0.047 in.) in diameter, mate front case (3) with
center case and then tighten bolts (2) to specified
torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Rear case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
20) Install oil strainer (1) to rear case (2).
Tightening torque
Strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
21) Install oil pump inner rotor (3), outer rotor (4) and
drive pin (5) to rear case.
2
1
3
(A)
4, “A”
“a”
I5JB0A331100-03
“A”
1
1
2, (a)
I5JB0A331101-02
“A”
1
2, (a)
2, (a)
3
I5JB0A331102-02
2
5
1
(a)
4
3
I5JB0A331103-01
Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-82
22) Clean mating surface of oil pump cover (1) and rear
case (2), apply sealant to rear case as shown in
figure by such amount that its section is 1.2 mm
(0.047 in.) in diameter, mate oil pump cover with rear
case and then tighten bolts (3) to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Oil pump cover bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
23) Clean mating surface of differential lock shift lever
case (1) and center case (5), apply sealant to center
case as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter, confirm the
each fork of lever case is in groove of the sleeve,
mate differential lock shift lever case with center
case and then tighten differential lock shift lever case
bolts (3) to which thread lock cement has been
applied and differential lock shift lever case dowel
bolts (4) to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
“B”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Differential lock shift lever case bolt (a): 23 N·m
(2.3 kgf-m, 17.0 lb-ft)
Differential lock shift lever case dowel bolt (b):
23 N·m (2.3 kgf-m, 17.0 lb-ft)
Input Gear Assembly Disassembly and
Reassembly
S5JB0E3326007
Front Output Shaft Assembly Disassembly and
Reassembly
S5JB0E3326008
Rear Output Shaft Assembly Disassembly and
Reassembly
S5JB0E3326009
“A”
3, (a)
3, (a)
1
2
I5JB0A331104-01
“A”
2
1
3, “B”, (a)
3, “B”, (a)
4, (b)
I5JB0A331105-03
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