Suzuki Grand Vitara JB419. Manual — part 79

Transfer: 3C-14

Transfer Assembly Disassembly and
Reassembly

S5JB0B3306009

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).

[A]: Flange is fixed type

19. Snap ring

41. Oil pump outer rotor

[B]: Flange is not fixed type

20. Washer

42. Oil pump inner rotor

1. Front oil seal No.1

: Apply grease 99000-25010 to oil seal lip.

21. Shim

43. Oil pump drive pin

2. Front case bolt

22. Reduction shift sleeve

44. Oil pump cover

3. Front case

23. Center differential assembly

45. Oil drain plug

: Apply sealant 99000-31260 to
plug thread.

4. Knock pin

24. Low gear

46. Transfer to transmission bolt

5. Oil pipe

25. Front drive shaft

47. Front oil seal No.2

: Apply grease 99000-25010 to oil
seal lip.

6. Input gear assembly

26. Thrust needle bearing

48. Rear oil seal

: Apply grease 99000-25010 to oil
seal lip.

7. Input gear plate bolt

27. Differential lock clutch sleeve

49. Transfer actuator bolt

8. Counter gear assembly

28. Front drive sprocket bush

50. Control cover

9. Needle bearing

29. Front drive sprocket

51. Flange (if equipped)

10. Center case

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

30. Rear output shaft assembly

52. Washer (if equipped)

11. Damper

31. Front output shaft assembly

53. Flange nut (if equipped)

: After tightening nut, caulk nut
securely.

12. 4L/N switch

32. Drive chain

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

13. Center differential lock switch

33. Rear case

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

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

14. Transfer actuator assembly

34. Oil level / filler plug

: Apply sealant 99000-31260 to plug
thread.

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

15. Control cover bolt

: Apply thread lock 99000-32110 to bolt
thread.

35. Harness bracket

: 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft)

16. Damper bolt

36. Harness bracket bolt

: 125 N

⋅m (12.5 kgf-m, 90.5 lb-ft)

37. Rear case bolt

: Do not reuse.

17. Breather pipe

38. Oil strainer

: Apply transfer oil.

18. O-ring

39. Oil strainer

19. Snap ring

40. Oil strainer bolt

1

1

I5JB0A331010-01

2

1

3

4

I5JB0A331011-01

3C-15 Transfer:

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: 3C-16

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

3C-17 Transfer:

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

special tool, if necessary.

Special tool
(A): 09913–76010

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

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

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

22) 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.

(A)

1

2

I5JB0A331027-01

1

2

I5JB0A331028-02

3

1

3

1

2

I5JB0A331029-01

1

2

I5JB0A331030-01

(A)

1

I5JB0A331033-01

2

3

1

1

2

4

3

I5JB0A331034-02