SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

TRANSFER 7D-13
To engage bevel pinion and gear correctly, it is prerequired to
install bevel pinion to transfer output retainer properly by using
adjusting shim (bevel pinion shim) as described on following
pages.
Shown in above page are relative positions of bevel pinion, gear
and transfer output retainer.
Install pinion shaft bearing (1) (front side) to bevel pinion
dummy (special tools, refer to previous page).
Install bevel pinion dummy (1), pinion shaft bearing (2) (rear
side) and special tool (A) by using special tool (B) to transfer
output retainer (refer to previous page for special tool num-
ber).
Special tool
(A) : 09922-76140
(B) : 09922-76150
(C) : 09922-76340
(D) : 09922-76430
Tighten bevel pinion nut (special tool) so that specified bear-
ing preload is obtained.
Pinion shaft bearing preload
(a) : 5.0 – 13.0 kg-cm (4.4 – 11.2 Ib-ft)
Measure height “b” in figure by using vernier caliper.
Calculate “c” by using measured value.
NOTE:
This installation requires no spacer or oil seal.
NOTE:
Before taking measurement, check for rotation by hand
more than 15 revolutions.
Distance “c”= Height “b”–Height “a”
“c”: Distance from retainer installation face to end face of bearing race
“b”: Height from retainer installation face to pinion dummy
“a”: Pinion dummy height

7D-14 TRANSFER
Install reduction driven gear to left case and right case and
then measure distance “d” as indicated in figure.
Calculate “f” by using measured value.
Obtain adjusting shim thickness by using calculated value in
following equation.
Select adjusting shim closest to calculated value from
among following available sizes.
Available shims thickness
: 0.30, 2.00, 2.03, 2.06, 2.09, 2.12, 2.15, 2.18, 2.21, 2.24 and
2.27 mm (0.012, 0.079, 0.080, 0.081, 0.082, 0.083, 0.085,
0.086, 0.087, 0.088 and 0.089 in.)
ASSEMBLY
1) Press-fit pinion shaft bearing outer races (front and rear) by
using special tools.
Special tool
(A) : 09913-75821
(B) : 09924-84510-005
2) Press-fit pinion shaft bearing (front side) by using special
tool, press and pinion shaft spacer (1) removed in procedure
UNIT DISASSEMBLY TRANSFER OUTPUT RETAINER.
Special tool
(A) : 09913-7581014.85 mm
(0.5846 in.)
(“e”/2) Distance “f”= Distance “d”+
Necessary
shim thick-
ness “h”Dimension Distance Distance
= “g”+ “c”– “f”
“f”: Distance from end face of left case to center shaft of reduction driven gear
“d”: Distance from end face of left case to cylinder section of reduction driven gear
“g”: Dimension marked on bevel pinion shaft

TRANSFER 7D-15
3) Install bevel pinion shaft with new pinion shaft spacer (1) to
transfer output retainer.
4) Press-fit pinion shaft bearing (rear side) (2) by using special
tool (and press).
Special tool
(A) : 09913-75810
5) Drive in oil seal (1) by using special tools and apply grease
to oil seal lip.
Special tool
(A) : 09913-75810
(B) : 09951-16090
“A” : Grease 99000-25010
Transfer bevel pinion shaft oil seal installing depth
“a” : 27.0 – 27.5 mm (1.063 – 1.083 in.)
6) Install flange (2) and tighten flange nut gradually so as rota-
tion torque of bevel pinion shaft to be in specified value.
Special tool
(A) : 09930-40113
Rotation torque for bevel pinion shaft
(b) : 0.5 – 1.3 N·m (0.05 – 0.13 kg-m, 0.30 – 0.90 lb-ft)
7) Caulk flange nut.CAUTION:
Press-fit bearing to such an extent that spacer is not
compressed.
2. Bevel pinion shaft
NOTE:
 If rotation torque of bevel pinion shaft exceeds specifi-
cation given below, replace pinion shaft spacer and
tighten flange nut.
 Before taking measurement of rotation torque, rotate
pinion shaft over ten rounds in advance.
1. Power wrench
3. Torque wrench

7D-16 TRANSFER
RIGHT CASE
1) Press-fit intermediate right bearing to intermediate shaft.
2) Install intermediate center oil seals (1) to case by using spe-
cial tool and apply grease to oil seal lip.
Special tool
(A) : 09924-84510-005
(B) : 09913-75821
“A” : Grease 99000-25010
Transfer intermediate center oil seals installing depth
“a” : 16.0 – 16.5 mm (0.630 – 0.650 in.)
“b” : 4.0 – 4.5 mm (0.157 – 0.177 in.)
3) Install intermediate shaft to right case, and install snap ring.
Special tool
(A) : 09952-76011
4) Install right case oil seal (1) to right case (2).
Special tool
(A) : 09913-75810
Transfer right case oil seal installing depth
“a” : 1.0 – 1.5 mm (0.039 – 0.059 in.)
5) Fill grease to inside of oil seal about 3 g (0.11 oz), and apply
grease to oil seal lip.
“A” : Grease 99000-25010
6) Install bevel gear shim(s) (2) selected in item BEVEL GEAR
SHIM ADJUSTMENT and driven gear bearing outer race (3)
to right case (1). CAUTION:
Use care the installation direction and depth of oil seals
for correct installation.

TRANSFER 7D-17
LEFT CASE
1) Install the bevel gear shim(s) selected in item BEVEL GEAR
SHIM ADJUSTMENT and driven gear bearing outer race to
left case.
2) Install reduction drive gear oil seal (1) to left case (2) by
using special tool.
Special tool
(A) : 09913-75810
Transfer reduction drive gear oil seal installing depth
“a” : 1.5 – 2.0 mm (0.059 – 0.078 in.)
3) Fill grease to inside of oil seal about 3 g (0.11 oz), and apply
grease to oil seal lip.
“A” : Grease 99000-25010
4) Press-fit drive gear bearings (right (2) and left (3)) to reduc-
tion drive gear (1).
Apply gear oil to ball part of bearing.
5) Install reduction drive gear (2) and reduction driven gear (3)
to left case (1).
TRANSFER ASSEMBLY
1) Clean mating surface of right case and left case (1), and
apply sealant to left case (1) by using a nozzle as shown in
figure by such amount that its section is 1.5mm (0.059 in) in
diameter.
“A” : Sealant 99000-31230

7D-18 TRANSFER
2) Tighten transfer case bolts to specified torque.
Tightening torque
Transfer case bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Install the bevel pinion shim(s) selected in preceding proce-
dure (TRANSFER OUTPUT RETAINER ADJUSTMENT),
install transfer output retainer (1) to transfer case and then
tighten retainer bolts (2) to specified torque.
Tightening torque
Transfer output retainer bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
BEVEL GEAR BACK LASH
MEASUREMENT
1) Install bolt to bolt hole of flange (2), set dial gauge measuring
tip at right angles to bolt (1) as shown in figure.
Take measurement backlash of pinion and bevel gear.
Transfer pinion & bevel gear backlash
: 0.1 – 0.2 mm (0.0039 – 0.0078 in.)
2) As final step, check gear tooth contact as follows.
a) After cleaning tooth surface of bevel gear (1), paint them
with gear marking compound evenly by using brush or
sponge etc.
b) Turn gear to bring its painted part in mesh with bevel pinion
and turn it back and forth by hand to repeat their contact.
c) Bring painted part up and check contact pattern, referring to
following chart.
If contact pattern is not normal, readjust or replace as nec-
essary according to instruction in chart.
NOTE:
If backlash exceeds specification given below, replace
bevel pinion shim (between transfer case and transfer
output retainer) and measure backlash again.
NOTE:
When applying red lead paste to teeth, be sure to paint
tooth surfaces uniformly. The paste must not be too dry
or too fluid.

TRANSFER 7D-19
NOTE:
 Be careful not to turn bevel gear more than one full
revolution, for it will hinder accurate check.
 If bevel gear back lash and bevel pinion shims are
adjusted properly, correct tooth contact should be pro-
vided.
If correct tooth contact is not provided even when they
are adjusted properly, however, there may be an
abnormal condition in worn tooth, transfer case or
retainer. Check each component and replace as neces-
sary.
TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY
NORMAL
HIGH CONTACT
Pinion is positioned too fat from the
center of drive bevel gear.
1) Decrease thickness of bevel pinion
shim and position pinion closer to
gear center.
2) Adjust drive bevel gear backlash to
specification.
LOW CONTACT
Pinion is positioned too close to the
center of drive bevel gear.
1) Increase thickness of bevel pinion
shim and position pinion farther
from gear center.
2) Adjust drive bevel gear backlash to
specification.

7D-20 TRANSFER
UNIT INSTALLATION
Install transfer assembly (2) by reversing removal procedure and
noting following points.
Tighten transfer mounting bolts (3) to specified torque.
Tightening torque
Transfer mounting bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Tighten rear mounting bracket bolts (1) to specified torque.
Tightening torque
Transfer rear mounting bracket bolts
(a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)These contact patterns indicate that the “offset” of
reduction driven gear is too much or too little. The rem-
edy is to change the division of the bevel gear shim(s).
These contact patterns, located on toe or heel on both
drive and coast sides, mean that 1) both pinion and
gear are defective, 2) retainer is not true, or 3) gear is
not properly seated on transfer case. The remedy is to
replace the defective member.
Irregular patterns: If the pattern is not oval, it means
that bevel gear is defective. High or low spots on tooth
surfaces or on the seat of bevel gear are the cause of
irregular patterns appearing on some teeth. The rem-
edy is to replace the pinion and gear set and, if the seat
is defective, so is transfer case. TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY
1. Transmission
1, (a)

TRANSFER 7D-21
Tighten mounting bolt and mounting bracket bolts and nuts
to specified torque.
Tightening torque
Transfer rear mounting bracket nuts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Transfer mounting bolt
(b) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
Transfer rear mounting bracket No.2 bolts
(c) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
Tighten transfer stiffener bolts (4) to specified torque.
Tightening torque
Transfer stiffener bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Tighten exhaust pipe bolts.
Tightening torque
Exhaust pipe bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Install right side drive shaft, refer to Section 4A.
Install propeller shaft and tighten propeller shaft bolts and
center support bolts to specified torque (refer to Section 4B).
Fill gear oil to transfer as specified, refer to OIL CHANGE of
ON-VEHICLE SERVICE.
Check oil level and leakage.
(a)
(b)
(c)
1. Transmission
2. Transfer
3. Stiffener
1. Exhaust No.1 pipe
2. Exhaust No.2 pipe
1
(a)(a)2

7D-22 TRANSFER
TIGHTENING TORQUE SPECIFICATION
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
Fastening partTightening torque
Nm kg-m lb-ft
Transfer oil level/filler and drain plugs 21 2.1 15.5
Transfer bevel gear nut 150 15.0 108.5
Transfer case bolts 23 2.3 17.0
Transfer output retainer bolts 50 5.0 36.5
Transfer mounting bolts 50 5.0 36.5
Transfer rear mounting bracket bolts 55 5.5 40.0
Transfer rear mounting bracket nuts 50 5.5 36.5
Transfer mounting bolt 55 5.5 40.0
Transfer rear mounting bracket No.2 bolts 55 5.5 40.0
Transfer stiffener bolts 50 5.0 36.5
Exhaust pipe bolts 50 5.0 36.5
MaterialRecommended SUZUKI products
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1216B
(99000-31230)Oil drain plug
Oil level plug
Mating surface of transfer case
09913-65135 09925-58210 09941-54911 09924-84510-005
Bearing puller Oil seal installer Bearing outer race
removerBearing installer attach-
ment