Suzuki Grand Vitara JB416 / JB420. Manual — part 191

3C-78 Transfer: Non-Shift Type (Transfer without Shift Actuator)

Repair Instructions

Transfer Oil Change

S5JB0A3326002

Refer to “Transfer Oil Change: Motor-Shift Type (Transfer with Shift Actuator)”.
The point which is different from the motor-shift type (transfer with shift actuator) is described.

Transfer oil capacity (Non-Shift Type)
Reference: 1.6 liters (3.4/2.8 US/lmp.pt)

Transfer Oil Level Check

S5JB0A3326003

Refer to “Transfer Oil Level Check: Motor-Shift Type (Transfer with Shift Actuator)”.

Transfer Oil Seal Removal and Installation

S5JB0A3326004

Refer to “Transfer Oil Seal Removal and Installation: Motor-Shift Type (Transfer with Shift Actuator)”.

Transfer Assembly Dismounting and Remounting

S5JB0A3326005

Refer to “Transfer Assembly Dismounting and Remounting: Motor-Shift Type (Transfer with Shift Actuator)”.

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-79

Transfer Assembly Components

S5JB0A3326006

37

36

9

38

(c)

32

(a)

25

20

(a)

(a)

40

(a)

27

(b)

(a)

A

OIL

28

29

31

33

1217G

30

26

10

10

19

9

OIL

9

OIL

23

1217G

24

1217G

22

21

35

A

9

OIL

9

OIL

16

OIL

18

17

15

14

13

12

11

9

OIL

5

4

6

2

(a)

2

(a)

34

(a)

3

7

8

39

1217G

1

A

OIL

41

(a)

1322

(a)

I5JB0A331084-06

3C-80 Transfer: Non-Shift Type (Transfer without Shift Actuator)

Transfer Assembly Disassembly and
Reassembly

S5JB0A3326007

Disassembly

1) Remove differential lock shift lever case (1).

2) Remove oil pump cover (1).

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

strainer (4) and drive pin (3).

4) Remove front case (1).

1. Front oil seal No.1

: Apply grease 99000-25010 to oil seal lip.

17. Differential lock clutch sleeve

33. Oil drain plug

: Apply sealant 99000-31260 to
plug thread.

2. Front case bolt

18. Front drive sprocket bush

34. Transfer to transmission bolt

3. Front case

19. Front drive sprocket

35. Front oil seal No.2

: Apply grease 99000-25010 to
oil seal lip.

4. Knock pin

20. Rear output shaft assembly

36. Rear oil seal

: Apply grease 99000-25010 to
oil seal lip.

5. Oil pipe

21. Front output shaft assembly

37. Damper

6. Input gear assembly

22. Drive chain

38. Damper bolt

7. Center case

: Apply sealant 99000-31260 to mating
surface of front case, differential lock shift
lever case and center case.

23. Rear case

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

39. Shift case

8. Differential lock shift lever case

24. Oil level / filler plug

: Apply sealant 99000-31260 to plug
thread.

40. Shift lever case bolt

9. Needle bearing

25. Rear case bolt

41. O-ring

10. Snap ring

26. Oil strainer

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

11. Washer

27. Oil strainer bolt

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

12. Shim

28. Oil pump outer rotor

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

13. Reduction shift sleeve

29. Oil pump inner rotor

: Do not reuse.

14. Center differential assembly

30. Oil pump drive pin

: Apply transfer oil.

15. Front drive shaft

31. Oil pump cover

16. Thrust bearing

32. Oil pump cover bolt

1

I5JB0A331085-01

1

I5JB0A331086-01

1

2

4

3

I5JB0A331013-01

1

I5JB0A331014-01

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-81

5) Remove rear case bolts (1), and then separate

center case (2) using special tool.

Special tool
(A): 09912–34510

6) 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.

7) Remove needle bearing (1) from center case (2)

using special tool, if necessary.

Special tool
(A): 09913–76010

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

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

9) Remove reduction shift sleeve (1) and center

differential (3) from rear output shaft (2).

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

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

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

output shaft (2).

1

I5JB0A331087-01

2

(A)

I5JB0A331016-02

1

2

3

4

I5JB0A331017-01

(A)

1

2

I5JB0A331088-01

1

2

3

4

5

I5JB0A331089-01

1

3

2

I5JB0A331090-02

1

1

2

3

4

I5JB0A331041-02

1

2

I5JB0A331022-01