Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 44

 

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Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 44

 

 

3C-71 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

Specifications

Tightening Torque Specifications

S5JB0E3317001

NOTE
The specified tightening torque is also described in the following.
“Transfer Assembly Components: Motor-Shift Type (Transfer with Shift Actuator)”

 

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A in related 
manual”.

Special Tools and Equipment

Recommended Service Material

S5JB0E3318001

NOTE
Required service material is also described in the following.
“Transfer Assembly Components: Motor-Shift Type (Transfer with Shift Actuator)”
“Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft 
Assembly Components: Motor-Shift Type (Transfer with Shift Actuator)”

 

Fastening part

Tightening torque

Note

N

m

kgf-m

lb-ft

Transfer oil level / filler plug

23

2.3 

17.0

)

Input gear plate bolt

23

2.3 

17.0

)

Rear case bolt

23

2.3 

17.0

)

 / )

Strainer bolt

10

1.0 

7.5

)

Oil pump cover bolt

23

2.3 

17.0

)

Control cover bolt

23

2.3 

17.0

)

Control cover dowel bolt

23

2.3 

17.0

)

Center differential lock switch

20

2.0 

14.5

)

4L/N switch

20

2.0 

14.5

)

Harness bracket bolt

10

1.0 

7.5

)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

 / ) / ) / )

Sealant

SUZUKI Bond No.1217G

P/No.: 99000–31260

)

 / ) / ) / ) / )

Thread lock cement

Thread Lock Cement Super 1322

P/No.: 99000–32110

)

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-72

Special Tool

S5JB0E3318002

09912–34510

09913–70123

Case separator

Bearing installing tool

)

)

 / ) / ) / )

09913–76010

09913–80113

Bearing installer

Bearing installer

)

 / ) / ) / ) / )

)

09913–84510

09913–85210

Bearing installer

Bearing installer

)

)

 / ) / )

09925–98210

09925–98221

Input shaft bearing installer

Bearing installer

)

 / )

)

09928–36510

09940–54910

Transfer cap

Front fork oil seal install 
driver

)

)

SUZUKI scan tool

This kit includes following 
items. 1. Tech 2, 2. PCMCIA 
card, 3. DLC cable, 4. SAE 
16/19 adapter, 5. Cigarette 
cable, 6. DLC loop back 
adapter, 7. Battery power 
cable, 8. RS232 cable, 9. 
RS232 adapter, 10. RS232 
loop back connector, 11. 
Storage case, 12.) / )

3C-73 Transfer: Non-Shift Type (Transfer without Shift Actuator)

Non-Shift Type (Transfer without Shift Actuator)

Precautions

Transfer Warning

S5JB0E3320001

Refer to “Transfer Warning: Motor-Shift Type (Transfer with Shift Actuator)”.

General Description

Transfer Construction

S5JB0E3321001

The aluminum transfer case directly connected to the back of the transmission contains the input gear, rear output 
shaft, front output shaft and drive chain.
The transfer has an oil pump to provide proper lubrication even under the strict condition of use.
The center differential is installed in the transfer. With the torque induction type LSD used in the center differential, the 
effect of LSD works when a rotation difference between front and rear wheels.
The differential lock lever is installed in shaft case. Center differential can be locked by operating differential lock lever, 
if necessary.

1

2

3

4

5

6

7

8

9

10

11

12

13

15

14

16

17

18

I5JB0A331083-02

1. Input gear

7. Front drive cam

13. Drive chain

2. Rear drive cam

8. Differential lock shift fork

14. Front output shaft

3. Reduction shift sleeve

9. Front drive shaft

15. Oil pipe

4. Reduction shift fork

10. Front drive sprocket bush

16. Oil pomp outer rotor

5. Center differential case

11. Front drive sprocket

17. Oil pump drive pin

6. Center differential cam follower

12. Rear output shaft

18. Oil pump inner rotor

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-74

Diagnostic Information and Procedures

Transfer Symptom Diagnosis

S5JB0E3324001

Before attempting to repair the transfer or related components for any reason other than mechanical failure, the 
condition and possible causes should be identified.
When any of these conditions occur, the following inspections should be made before disassembling the transfer.
• Check transfer for oil level and oil deterioration.

Refer to “Transfer Oil Change: Non-Shift Type (Transfer without Shift Actuator)”.

After performing the above inspections, refer to the following diagnosis table.

Repair Instructions

Transfer Oil Change

S5JB0E3326001

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

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

Transfer Oil Level Check

S5JB0E3326002

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

Transfer Oil Seal Removal and Installation

S5JB0E3326003

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

Transfer Assembly Dismounting and 
Remounting

S5JB0E3326004

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

Condition

Possible cause

Correction / Reference Item

Gear slipping out of mesh Worn control cover shift shaft

Replace referring to “Transfer Assembly 
Inspection: Motor-Shift Type (Transfer with 
Shift Actuator)”.

Worn shift fork or sleeve

Replace referring to “Transfer Assembly 
Inspection: Motor-Shift Type (Transfer with 
Shift Actuator)”.

Weak or damaged control cover shift 
shaft spring

Replace referring to “Transfer Assembly 
Inspection: Motor-Shift Type (Transfer with 
Shift Actuator)”.

Worn bearings on input gear or counter 
gear

Replace referring to “Transfer Assembly 
Inspection: Motor-Shift Type (Transfer with 
Shift Actuator)”.

Worn chamfered tooth on sleeve or gear Replace sleeve and gear referring to “Transfer 

Assembly Inspection: Motor-Shift Type 
(Transfer with Shift Actuator)”
.

Missing or disengagement of circlip(s)

Repair or replace referring to “Transfer 
Assembly Inspection: Motor-Shift Type 
(Transfer with Shift Actuator)”
.

Noise

Inadequate or insufficient transfer oil

Replenish referring to “Transfer Oil Change: 
Non-Shift Type (Transfer without Shift 
Actuator)”.

Damaged or worn bearing(s)

Replace referring to “Transfer Assembly 
Inspection: Motor-Shift Type (Transfer with 
Shift Actuator)”.

Damaged or worn gear(s)

Replace referring to “Transfer Assembly 
Inspection: Motor-Shift Type (Transfer with 
Shift Actuator)”.

Damaged or worn chamfered tooth on 
sleeve or gear

Replace referring to “Transfer Assembly 
Inspection: Motor-Shift Type (Transfer with 
Shift Actuator)”.

 

 

 

 

 

 

 

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