Suzuki Grand Vitara JB416 / JB420. Manual — part 192

3C-82 Transfer: Non-Shift Type (Transfer without Shift Actuator)

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

output shaft (2).

13) 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.

14) Remove snap ring (1), and then rear output shaft

assembly (2) from rear case (3).

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

end rod or the like, if necessary.

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

special tool, if necessary.

Special tool
(A): 09913–76010

17) Remove input gear plate (1), and then remove input

gear assembly (3) from front case (2).

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

using flat end rod or the like, if necessary.

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2

I5JB0A331023-01

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2

3

5

4

I5JB0A331024-01

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2

3

I5JB0A331025-01

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2

I5JB0A331026-01

(A)

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2

I5JB0A331027-01

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2

3

I5JB0A331091-01

1

2

I5JB0A331030-01

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-83

Reassembly

1) Install 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 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).

(A)

1

I5JB0A331033-01

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2

I5JB0A331092-01

1, (a)

I5JB0A331093-03

(A)

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2

“a”

I5JB0A331036-02

(A)

1, “A”

2

“a”

I5JB0A331094-04

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2

3

I5JB0A331025-01

3C-84 Transfer: Non-Shift Type (Transfer without Shift Actuator)

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).

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

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4

I5JB0A331024-01

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I5JB0A331039-01

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I5JB0A331040-01

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4

I5JB0A331041-02

[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.)

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2

[A]

I5JB0A331095-02

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2

I5JB0A331096-01

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3

4

2

I5JB0A331097-01

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-85

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

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)

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2

3

I5JB0A331098-02

1

(A)

2

“a”

I5JB0A331099-02

2

1

3

(A)

4, “A”

“a”

I5JB0A331100-03

“A”

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1

2, (a)

I5JB0A331101-02