Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 256

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

Repair Instructions

Transfer Oil Level Check

S6JB0A3316001

1) Lift up vehicle and check oil leakage.
2) Remove oil level/filler plug (1) and check oil level is

between 0 and 10 mm (0 and 0.394 in.) from the
lower end of oil level / filler plug hole (2).
If oil level is not in the range, add specified oil up to
plug hole.

Transfer Oil Change

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1) Before changing oil, be sure to stop engine and lift

vehicle horizontally.

2) Check leakage.

If leakage exists, correct it.

NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain oil.
5) Apply sealant to thread of drain plug (1), and tighten

it to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Transfer oil drain plug (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)

6) Pour new specified oil up to lower end of oil level /

filler plug hole (3).

NOTE
It is highly recommended to use API GL-5
80W-90 gear oil.

Transfer oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)

Transfer oil capacity (Motor-Shift Type)
Reference: 1.5 liters (3.2/2.6 US/lmp. pt)

7) Apply sealant to thread of level / filler plug, and then

tighten it to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Transfer oil level / filler plug (b): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)

“a”. 0 – 10 mm (0 – 0.394 in.)

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“a”. 0 – 10 mm (0 – 0.394 in.)

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

Transfer Oil Seal Removal and Installation

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Removal

1) Lift up vehicle and drain transfer oil.
2) Remove front propeller shaft and/or rear propeller

shaft referring to “Propeller Shaft Removal and
Installation in Section 3D”.

3) Remove front oil seal No.1 (1) and/or rear oil seal (2)

using flat end rod or the like.

Installation

1) Install new oil seal using special tool and plastic

hammer, and then apply grease to oil seal lip.

: Grease 99000–25010 (SUZUKI Super Grease
A)

Special tool
(A): 09913–70123

2) Install front propeller shaft and/or rear propeller shaft

referring to “Propeller Shaft Removal and Installation
in Section 3D”.

3) Fill transfer oil referring to “Transfer Oil Change:

Motor-Shift Type (Transfer with Shift Actuator)”.

Transfer Switch Removal and Installation

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Removal
Remove HVAC control module referring to “HVAC
Control Module Removal and Installation in Section 7A”,
and then remove transfer switch (1) from center cluster
(2).

Installation
Reverse removal procedure.

2

1

I5JB0A331031-01

(A)

(A)

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1

2

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

Transfer Switch Inspection

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Check continuity between following terminals when
transfer switch (1) operated at each position.

4WD Control Module Removal and Installation

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Removal

1) Disconnect negative (–) cable from battery.
2) If the vehicle is equipped with air bag system,

disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.

3) Disconnect connectors from 4WD control module

(1).

4) Remove 4WD control module with TCM by removing

its nuts, and then separate 4WD control module and
TCM.

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”.

Switch position

Terminal

†

(2)

1 – 2

N (3)

1 – 2 – 3

4H (4)

1 – 3

4H-lock (5)

1 – 3 – 4

4L-lock (6)

1 – 4

[A]: Transfer switch connector (harness side view)

[A]

6 5 4 3 2 1

6

5

4

3

2

1

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1

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

Transfer Assembly Dismounting and
Remounting

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Dismounting

1) Shift transfer to 4H position operating transfer

switch.

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

referring to “Transmission Shift Control Lever
Removal and Installation: For Petrol Engine Model in
Section 5B” or “Transmission Shift Control Lever
Removal and Installation: For Diesel Engine Model
in Section 5B”.

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”.

6) Remove exhaust center pipe (3) referring to

“Exhaust Pipe and Muffler Removal and Installation:
For Petrol Engine Model in Section 1K” or “Exhaust
System Components: For Diesel Engine Model in
Section 1K”.

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 (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)” and “Gear Shift Control Lever
Rear Case Assembly Components: For Petrol Engine
Model in Section 5B” or “Gear Shift Lever Case
Assembly Components: For Diesel Engine Model in
Section 5B”.

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

Motor-Shift Type (Transfer with Shift Actuator)”.

• Connect battery and check for function.

1

4

3

6

5

2

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1

2

3

I5JB0A331007-02

1

2

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