Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 257

3C-59 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

Transfer Assembly Components

S6JB0A3316008

11

16

44

45

42

43

41

40

9

(c)

(a)

39

38

(b)

37

(a)

37

35

(a)

(a)

10

33

32

30

31

34

1217G

48

9

28

27

9

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

9

12

54

(d)

13

17

(d)

15

(a)

1322

49

50

18

OIL

OIL

18

14

(b)

[A]

[B]

51

52

53

(e)

OIL

OIL

OIL

A

A

1217G

1217G

31

1217G

(a)

(a)

I5JB0B330001-11

[A]: Flange is fixed type

20. Washer

41. Oil pump outer rotor

[B]: Flange is not fixed type

21. Shim

42. Oil pump inner rotor

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-60

Transfer Assembly Disassembly and
Reassembly

S6JB0A3316009

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).

1. Front oil seal No.1

: Apply grease 99000-25010 to oil seal lip.

22. Reduction shift sleeve

43. Oil pump drive pin

2. Front case bolt

23. Center differential assembly

44. Oil pump cover

3. Front case

24. Low gear

45. Oil drain plug

: Apply sealant 99000-31260 to
plug thread.

4. Knock pin

25. Front drive shaft

46. Transfer to transmission bolt

5. Oil pipe

26. Thrust needle bearing

47. Front oil seal No.2

: Apply grease 99000-25010 to oil
seal lip.

6. Input gear assembly

27. Differential lock clutch sleeve

48. Rear oil seal

: Apply grease 99000-25010 to oil
seal lip.

7. Input gear plate bolt

28. Front drive sprocket bush

49. Transfer actuator bolt

8. Counter gear assembly

29. Front drive sprocket

50. Control cover

9. Needle bearing

30. Rear output shaft assembly

51. Flange (if equipped)

10. Center case

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

31. Front output shaft assembly

52. Washer (if equipped)

11. Damper

32. Drive chain

53. Flange nut (if equipped)

: After tightening nut, caulk nut
securely.

12. 4L/N switch

33. Rear case

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

54. Control cover dowel bolt

13. Center differential lock switch

34. Oil level / filler plug

: Apply sealant 99000-31260 to plug
thread.

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

14. Transfer actuator assembly

35. Harness bracket

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

15. Control cover bolt

: Apply thread lock 99000-32110 to bolt
thread.

36. Harness bracket bolt

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

16. Damper bolt

37. Rear case bolt

: 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft)

17. Breather pipe

38. Oil strainer

: 125 N

⋅m (12.5 kgf-m, 90.5 lb-ft)

18. O-ring

39. Oil strainer

: Do not reuse.

19. Snap ring

40. Oil strainer bolt

: Apply transfer oil.

1

1

I5JB0A331010-01

2

1

3

4

I5JB0A331011-01

3C-61 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

4) Remove front output flange follows, if equipped.

a) Uncaulk front output flange nut.
b) Remove front output flange nut while holding

flange by using special tool.

Special tool
: 09922–66021

5) Remove oil pump cover (1).

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

strainer (4) and drive pin (3).

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

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

separate center case (3) using special tool.

Special tool
(A): 09912–34510

9) 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.

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

using special tools, if necessary.

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

1

I5JB0A331012-01

1

2

4

3

I5JB0A331013-01

1

I5JB0A331014-01

1

2

I5JB0A331015-01

3

(A)

I5JB0A331106-01

1

2

3

4

I5JB0A331017-01

(A)

(B)

1

2

I5JB0A331018-01

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-62

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

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

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

and low gear from rear output shaft (2).

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

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

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

output shaft (2).

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

output shaft (2).

16) 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.

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

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

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

end rod or the like, if necessary.

1

2

3

4

5

I5JB0A331019-01

1

2

I5JB0A331020-02

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