Suzuki Grand Vitara JB627. Manual — part 164

3C-60 Transfer:

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

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

13) Remove differential lock clutch sleeve (1) from rear

output shaft (2).

14) Remove front drive sprocket bush (1) from rear

output shaft (2).

15) Take out front drive sprocket (1), front output shaft

assembly (2), drive chain (3) and needle bearing (4)
from rear case (5) all at once.

16) Remove snap ring (1), and then remove rear output

shaft assembly (2) from rear case (3).

17) Remove rear oil seal (1) from rear case (2) using flat

end rod or the like, if necessary.

18) Remove needle bearing (1) from rear case (2) using

special tool, if necessary.

Special tool
(A): 09913–76010

19) Remove input gear plate bolts (1) from front case (2).

1

1

2

3

4

I5JB0A331021-01

1

2

I5JB0A331022-01

1

2

I5JB0A331023-01

1

2

3

5

4

I5JB0A331024-01

1

2

3

I5JB0A331025-01

1

2

I5JB0A331026-01

(A)

1

2

I5JB0A331027-01

1

2

I5JB0A331028-02

Transfer: 3C-61

20) Remove input gear assembly (1) and counter gear

assembly (2) from front case (3) using plastic
hammer.

21) Remove front oil seal No.2 (1) from front case (2)

using flat end rod or the like, if necessary.

Reassembly

1) Install new front oil seal No.2 to front case (1) using

special tool, and then apply grease to oil seal lip.

: Grease 99000–25010 (SUZUKI Super Grease A)

Special tool
(A): 09913–85210

2) Install counter gear assembly (1) to front case (2),

and then install input gear assembly (3).

NOTE
Install input gear plate (4) so as not to hit
counter gear assembly.

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)

3

1

3

1

2

I5JB0A331029-01

1

2

I5JB0A331030-01

(A)

1

I5JB0A331033-01

2

3

1

1

2

4

3

I5JB0A331034-02

1, (a)

I5JB0A331035-03

3C-62 Transfer:

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.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)

Distance between case and oil seal “a”
: 3.5 – 4.5 mm (0.138 – 0.177 in.)

Special tool
(A): 09913–70123

6) Install rear output shaft assembly (1) to rear case (2),

and then install snap ring (3).

7) Install front drive sprocket (1), front output shaft

assembly (2), drive chain (3) and needle bearing (4)
into rear case (5).

8) Install front drive sprocket bush (1) into front drive

sprocket (2).

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 (1)

and needle bearings (2) to rear output shaft (3).

(A)

1

2

“a”

I5JB0A331036-02

“a”

(A)

1, “A”

2

1

2

I5JB0A331037-04

1

2

3

I5JB0A331038-01

1

2

3

5

4

I5JB0A331024-01

1

2

I5JB0A331039-01

1

2

I5JB0A331040-01

1

1

2

3

4

I5JB0A331041-02

Transfer: 3C-63

11) Install low gear (3), center differential (4) and

reduction shift sleeve (1) to rear output shaft (2).

12) 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
become specified value.

Clearance between shim and washer
: 0.1 – 0.3 mm (0.004 – 0.012 in.)

Available shim thickness

13) Remove used snap ring, and then install new snap

ring (2) and needle bearing (1) to rear output shaft
(3).

14) Install needle bearings (1) to center case (2) using

special tools as shown in figure.

Distance between case and needle bearing “a”
: 0 – 0.5 mm (0 – 0.008 in.)

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

[A]: Rear case side

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

2

4

[A]

4

3

I5JB0A331042-02

1

3

2

4

I5JB0A331043-01

1

2

3

I5JB0A331044-02

1

2

(B)

(A)

“a”

I5JB0A331045-02