SUZUKI GRAND VITARA 1987 Service Repair Manual

Fig. 13-63@High and reverse gear shift fork
@Low speed gear shift fork
NOTE:
Gear shift fork
the same.
*eFig. 13-65
Note that 3 shift shafts individually have a
locating ball and locating spring, and that 2
interlock balls and an interlock roller are used
between shafts as shown in Fig. 1364.
Fig. 13-64
Install low, high and reverse shafts in that order.
1) Install 3 locating springs into 3 holes in
upper case.Fit locating ball ( @ in Fig.
13-64) on top of locating spring in hole.
1. Locating spring2. Locating ball @3. Upper case
2) Insert low speed gear shift shaft into upper
case and low speed shift fork in the direction
as shown in Fig. 1366.
9-r
Fig. 13-66
3) As shown below, push down low speed gear
shift shaft locating ball to pass shaft over it
and keep inserting shaft until locating ball
fits in center slot of 3 continuous slots in
shaft.
Drive shift yoke pin into fork and shaft.
13-20

Fig. 13-67
4) Install interlock ball ( @ in Fig. 1364) and
locating ball ( @ in Fig. 13-64) in upper case.
After installing interlock roller ( @ in Fig.
1364) in high speed gear shift shaft and
insert shaft into upper case as described in
2) and 3).
Fork should be installed in such direction as
shown in Fig. 13-68. Then drive shift yoke
pin until it becomes flush with outer surface
of fork.
Fig. 13-68
5) Install interlock ball ( @ in Fig. 1364) and
locating ball ( @ in Fig. 13-64) into upper
case. Then insert reverse gear shift shaft
into upper case as described in 2) and 3).
[Yokes]
1) Install low speed .gear shift yoke as shown
below, using care for its direction.
Low speed ear shift yoke
Yoke pin3
%-JJ
Yoke pit!\
\Yoke pin
Reverse gaar shift5th gear selectlim springreturn spring5th gear shiftReverse gear shift yokelim yoke
Fig. 13-70
2) Install reverse gear shift yoke and 5th gear
shift yoke as shown below. Use care for
installing direction of each part.
Between 2 springs, shorter one is 5th select
return spring.
Low speed ear shift yoke
Yoke pin3
Yoke pi,/I\;oke pin
Reverse gear shift5th gear selectlim springreturn spring5th gear shiftReverse gear shift yokelim yoke
Fig. 13-71
13-21

Fig. 13-72Fig. 13:74 Main shaft and input shaft assembly
Transmission Lower Case and Upper Case
1) With counter shaft ass’y, reverse idle gear
and reverse gear shaft installed in lower
case, check to ensure that bearing stopper
rings @ are fitted in both sides of lower
case as shown below.
Also check for 2 knock pins 0.
Fig. 13-75
Fig. 13-73
2) Make sure that mating surfaces of both lower
and upper cases are clean.
3) Install main shaft and input shaft ass’y in
lower case.Fig. 13-76
13-22

4) Uniformly apply sealant (SUZUKI BOND
NO. 1215, 99000-31110) to mating surface
of lower case.
Extension Case
1) Check to ensure that knock pins @ are
fitted.
Fig. 13-77Fig. 13-79
5) Install upper case to lower case by matching
3 shift forks with 3 grooves in synchronizer
sleeve on main shaft respectively.
Fig. 13-78 CiJ Shift forks
2)Apply grease (SUZUKI SUPER GREASE
A 99000-25010) to oil seal lip.
3) Clean surface of extension case to mate
with transmission case and uniformly apply
sealant (SUZUKI BOND No. 1215, 99000-
31110).
Fig. 13-806) Tighten case bolts to specification.
Tightening torque N.mkg-mlb-ftfor transmissioncase bolts18-281.8-2.813.5-20.0
4) Make sure that 3 shift shafts are in neutral
position as shown in Fig. 13-23.
5) Install extension case to transmission case.
6) Tighten case bolts to specification.
Tightening torque N.mkg-mlb-ftfor extension casebolts18-281.8-2.813.5-20.0
13-23

7) Apply thread lock agent (THREAD LOCK
CEMENT SUPER “1333B” 99000-32020)
to thread of reverse gear shift rim bolt,
And tighten rim bolt to. extension case to
specified torque.
Tightening torque ,,,”kg-mlb-ftfor reverse gear
shift rim bolt14-20 1.4-2.0 10.5-14.0
\
Fig. 13-81
Input Shaft Bearing Retainer
1
2
)Apply grease (SUZUKI SUPER GREASE A
99000-25010) to oil seal lip.
‘) Clean surface of retainer to mate with
transmission case and uniformly apply
sealant (SUZUKI BOND No. 1215, 99000-
31110).
Fig. 13-82
3) Tighten retainer bolts to specification.
h
Tightening torque N*mkg-mlb-ft
forretainerbolts18-281.8-2.813.5-20.0
4) Check transmission input shaft for easy
rotation by hand.
5) Check each select and shift shaft for opera-
tion.
Clutch Release Bearing
Before installing bearing, apply grease (SUZUKI
SUPER GREASE A 99000-25010) to inner
surface of clutch release bearing.
Fig. 13-83
Clutch release bearing
Apply grease (SUZUKISUPER GREASE A,99000-25010)I.D. recess
Input shaft
Before remounting transmission ass’y to engine
and car body, apply grease (SUZUKI SUPER
GREASE I, 99000-25210) to input shaft.
Fig. 13-841. Apply grease
Others
Upon completion of reassembly and installa-
tion of transmission ass’y in car body, pour
specified amount of transmission oil into trans-
mission, and check carefully for oil leakage.
Refer to p. 13-25 for oil to be used and speci-
fied amount.13-24

13-7. MAINTENANCE SERVICES
Transmission Oil
Before changing oil, check for oil leakage first
and correct defects, if any. Fill specified new oil
in specified amount.
Oil capacity1.3 litres
(2.75/2.29 US/Imp. pt.)
IOil specificationGear oil, SAE 8OW-90,75W-80
or 75W-90I
It is. highly recommended to use SAE 75W-90.
gear oil.
For viscosity chart, refer to P. I-20.
Fig. 13-85
@ Oil filler plug
@ Oil drain plup@ Oil level plug
After filling transmission with oil, torque oil
filler and drain plugs to specification.
Tightening torque N.m
for oil drain andkg-mlb-ft
filler plug18-28 1.8-2.8 13.5-20.0
Tightening torque
for oil level pluglo-161.0-1. 7.5-11.5
NOTE:
Whenever car was hoisted for any other service
work than oil change, also be sure to check for
oil leakage.
When installing oil drain and filler plugs to
transmission case,aipply sealant (SUZUKI
BOND No.1215, 99000-31110) to thread part
of plug.
13-25

13-8. RECOMMENDED TORQUE SPECIFICATION
Be sure to torque each bolt and nut according to specification given below, whenever loosened.
If specified torque for particular bolt or nut is not included in the list, refer to page O-13.
System
Gear shifting
control
TransmissionI
Fastening parts
8.Extension case bolt
13-25

SECTION 14
TRANSFER GEAR BOX
CONTENTS
14-l.GENERAL DESCRIPTION................................. 14-2
14-2.SELECTIVE FLOWS OF TRANSFER DRIVE..................14-3
14-3.GEAR RATIO DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
14-4.TRANSFER SERVICES NOT REQUIRING
TRANSFER REMOVAL . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . 14-5
14-5.REMOVAL.............................................14-6
14-6.DISASSEMBLY..........................................14-8
14-7.INSPECTION OF COMPONENTS........................... 14-12
14-8.REASSEMBLY......................................... 14-14
14-9.MAINTENANCE SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22 12
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23
14-1
14-10.

14-1. GENERAL DESCRIPTION
The transfer gear box is an auxiliary transmission for on-off control of two-speed drive transmitted to
both front and rear axles concurrently and provides additional speed reductions, HIGH and LOW, for any
selection of main transmission gears.
The functions of this auxiliary transmission are mainly two-selection between four-wheel drive (front and
rear axles) and two-wheel drive (rear axle) and between HIGH and LOW for four-wheel drive. Three
propeller shafts are associated with the gear box.
These functions are accomplished by means of four shafts arranged in three-axis configuration and two
sliding clutches. The selection is effected by actuating these clutches from a single control lever located
beside the driver’s seat. The gear box is mounted on a chassis frame.
1.Flange
2.Oil seal
3.Circlip
4.Bearing
5.Nut6.Input shaft
7.Bearing
8.Counter shaft lock plate
9.O-ring
10.Counter shaft
11.Bearing
12.Spacer
13.Thrust washer
14.Counter gear
15.Flange
16.Oil seal
17.Circlip
18.Bearing
19.Output front shaft
20.Bearing
21.Circlip
22.Sleeve
23.Hub
24.Bearing
25.Thrust washer
26.Bearing
27.Output high gear
28.Sleeve
29.Output rear shaft
30.Output low gear
31.Bearing
32.Speedometer drive gear
33.Bearing
34.Retainer
35.Oil seal
36.Speedometer driven gear
37.Speedometer gear case
38.Oil seal
39.Shim
40.Flange
41.Washer
Fig. 14- 1
14-2
Fig. 14-1

14-2. SELECTIVE FLOWS OF TRANSFER DRIVE
2-Wheel Drive (Rear-Wheel Drive)
Rear shifter fork pushes rear clutch sleeve into
“high” gear, thus coupling the gear to output
rear shaft.
Drive flows from input shaft to output rear shafttra”SmiSSion
through big gear, “high” gear and rear clutch.
Gear shift control lever position
a-wheel drive
(Rear wheel drive)
Fig. 14-2
4-Wheel Drive HIGH (All-Wheel Drive on HIGH)
Under the conditions of rear-wheel drive,
described above, front shifter fork pushes the
sleeve of front clutch onto the toothed clutch From .
ring, thus coupling output rear shaft to output transm’ss’on
shaft runefront shaft. Front shaft and rear
together on HIGH.
Gear shift control lever position
4-wheeldrive HIGH
To front wheel
Fig. 14-314-3