Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 40

3C-55 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

Installation
Reverse removal procedure for installation noting the
following.
• Connect 4WD control module connectors securely.
• If the vehicle is equipped with air bag system, be sure

to enable air bag system after 4WD control module is
back in place.
Refer to “Enabling Air Bag System in Section 8B in
related manual”.

Transfer Assembly Dismounting and
Remounting

S5JB0E3316007

Dismounting

1) Shift transfer to 4H position operating transfer

switch.

2) Disconnect negative (–) cable from battery.
3) Remove gear shift control lever (for M/T model)

referring to “Transmission Shift Control Lever
Removal and Installation in Section 5B in related
manual”.

4) Drain transfer oil.
5) Remove front propeller shaft (1) and rear propeller

shaft (2) referring to “Propeller Shaft Removal and
Installation in Section 3D in related manual”.

6) Remove exhaust center pipe (3) referring to

“Exhaust Pipe and Muffler Removal and Installation
in Section 1K in related manual”.

7) Disconnect transfer actuator connector (4), center

differential lock switch connector (5), 4L/N switch
connector (6).

8) Support engine rear mounting member (1) with

transmission jack (2).

9) Remove engine rear mounting bolts (3), and then

slant the transmission with transfer.

10) Remove gear shift control lever rear case from

transfer (for M/T model).

11) Remove transfer to transmission bolts (upper side),

and then install engine rear mounting member with
transmission and transfer.

12) Support transfer assembly (1) with transmission

jack.

13) Remove transfer to transmission bolts (lower side)

(2), and then lower transfer assembly.

Remounting
Reverse dismounting procedure for remounting noting
the following.
• Tighten each bolts and nuts referring to “Transfer

Assembly Components: Motor-Shift Type (Transfer
with Shift Actuator)”, “Propeller Shaft Construction in
Section 3D in related manual”, “Exhaust System
Components in Section 1K in related manual”, “Gear
Shift Control Lever Rear Case Assembly Components
in Section 5B in related manual” and “Transmission
Shift Control Lever Removal and Installation in
Section 5B in related manual”.

• Set each clamp for wiring securely.
• Fill transfer oil referring to “Transfer Oil Change:

Motor-Shift Type (Transfer with Shift Actuator) in
related manual”.

• Connect battery and check for function.

1

4

3

6

5

2

I5JB0A331006-01

1

2

3

I5JB0A331007-02

1

2

I5JB0A331008-01

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-56

Transfer Assembly Components

S5JB0E3316008

11

16

44

45

42

43

41

40

9

(c)

(a)

39

38

(b)

37

(a)

37

35

(a)

(a)

1217G

10

1217G

33

32

30

31

1217G

34

1217G

48

A

OIL

9

28

27

OIL

9

OIL

OIL

9

OIL

9

OIL

19

29

19

47

A

26

25

24

23

22

4

5

7

6

21

20

OIL

9

OIL

2

(a)

2

3

8

(a)

46

(a)

1

A

9

OIL

12

(d)

13

17

(d)

15

(a)

1322

49

50

18

OIL

18

14

(b)

I5JB0A331009-06

3C-57 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

Transfer Assembly Disassembly and
Reassembly

S5JB0E3316009

Disassembly

1) Remove harness bracket (1).

2) Remove center differential lock switch (1) and 4L/N

switch (2).

3) Remove transfer actuator assembly (3) and breather

pipe (4).

4) Remove oil pump cover (1).

5) Remove oil pump inner rotor (1), outer rotor (2), oil

strainer (4) and drive pin (3).

1. Front oil seal No.1

: Apply grease 99000-25010 to oil seal lip.

20. Washer

39. Oil strainer bolt

2. Front case bolt

21. Shim

40. Oil pump outer rotor

3. Front case

22. Reduction shift sleeve

41. Oil pump inner rotor

4. Knock pin

23. Center differential assembly

42. Oil pump drive pin

5. Oil pipe

24. Low gear

43. Oil strainer bolt

6. Input gear assembly

25. Front drive shaft

44. Oil pump cover bolt

7. Input gear plate bolt

26. Thrust needle bearing

45. Oil drain plug

: Apply sealant 99000-31260 to
plug thread.

8. Counter gear assembly

27. Differential lock clutch sleeve

46. Transfer to transmission bolt

9. Needle bearing

28. Front drive sprocket bush

47. Front oil seal No.2

: Apply grease 99000-25010 to oil
seal lip.

10. Center case

: Apply sealant 99000-31260 to mating
surface of front case, transfer control
cover and center case.

29. Front drive sprocket

48. Rear oil seal

: Apply grease 99000-25010 to oil
seal lip.

11. Damper

30. Rear output shaft assembly

49. Transfer actuator bolt

12. 4L/N switch

31. Front output shaft assembly

50. Control cover

13. Center differential lock switch

32. Drive chain

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

14. Transfer actuator assembly

33. Rear case

: Apply sealant 99000-31260 to mating
surface of rear case, oil pump cover and
center case.

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

15. Control cover bolt

: Apply thread lock 99000-32110 to bolt
thread.

34. Oil level / filler plug

: Apply sealant 99000-31260 to plug
thread.

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

16. Damper bolt

35. Harness bracket

: 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft)

17. Breather pipe

36. Harness bracket bolt

: Do not reuse.

18. O-ring

37. Rear case bolt

: Apply transfer oil.

19. Snap ring

38. Oil strainer

1

1

I5JB0A331010-01

2

1

3

4

I5JB0A331011-01

1

I5JB0A331012-01

1

2

4

3

I5JB0A331013-01

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-58

6) Remove front case (1) using plastic hammer.

7) Remove rear case bolts (1) and clamp (2) and then

separate center case (3) using special tool.

Special tool
(A): 09912–34510

8) Remove knock pin (1) and oil pipe (2) from center

case (4) and remove front oil seal No.1 (3) using flat
end rod or the like, if necessary.

9) Remove needle bearings (1) from center case (2)

using special tools, if necessary.

Special tool
(A): 09913–76010
(B): 09925–98210

10) Remove needle bearing (1), snap ring (2), washer

(3) and shim(s) (4) from rear output shaft (5).

11) Remove reduction shift sleeve (1), center differential

and low gear from rear output shaft (2).

12) Remove needle bearings (1), front drive shaft (2)

and thrust needle bearing (4) from rear output shaft
(3).

1

I5JB0A331014-01

1

2

I5JB0A331015-01

3

(A)

I5JB0A331106-01

1

2

3

4

I5JB0A331017-01

(A)

(B)

1

2

I5JB0A331018-01

1

2

3

4

5

I5JB0A331019-01

1

2

I5JB0A331020-02

1

1

2

3

4

I5JB0A331021-01