SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-44
23) Remove differential cover.
24) To measure bevel gear backlash, set dial gauge at
right angle to bevel gear tooth, fix drive bevel pinion
and read dial gauge while moving bevel gear.
If bevel gear backlash is out of specification, repeat
Step 22).
NOTE
• Be sure to apply measuring tip of dial
gauge at right angles to convex side of
tooth.
• Measure at least 4 points on drive bevel
gear periphery.

Drive bevel gear back lash
0.1 – 0.2 mm (0.004 – 0.008 in.)Special tool
(A): 09900–20607
(B): 09900–20701
25) As final step, check gear tooth contact as follows.
a) After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or
sponge etc.
b) Turn gear to bring its painted part in mesh with drive 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 the following table. If contact pattern is not normal,
readjust or replace as necessary according to instruction in the table.
NOTE
Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.

I5RW0A320057-01
A: Paint gear marking compound evenly
1
A
I5JB0A321040-02

Downloaded from www.Manualslib.com manuals search engine 3B-45 Differential:
Tooth Contact Pattern Diagnosis and Remedy
Normal
High Contact
Pinion is positioned too far from the center of drive
bevel gear (1).
• Increase thickness of pinion (2) height adjusting
shim and position pinion closer to gear center.
• Adjust drive bevel gear backlash to specification.
Low Contact
Pinion is positioned too close to the center of drive
bevel gear (1).
• Decrease thickness of pinion (2) height adjusting
shim and position pinion farther from gear center.
• Adjust drive bevel gear backlash to specification.
If adjustment is impossible, replace differential carrier.
• Check seating of bevel gear or differential case. (Check bevel
gear for runout.)
• If adjustment is impossible, replace drive bevel gear and pinion
set or differential carrier.
Replace drive bevel gear and pinion set or differential case.
I5JB0A321041-05
IYSQ01321072-01
IYSQ01321073-01
IYSQ01321074-01IYSQ01321076-01
IYSQ01321077-01
IYSQ01321078-01
IYSQ01321079-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-46
26) Clean mating surface of differential carrier (1) and
differential cover, apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate differential cover with
differential carrier, and then tighten bolts to specified
torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential cover bolt: 23 N·m (2.3 kgf-m, 17.0
lb-ft)
27) Assemble coupling case as follows.
a) Install bearing using special tool and hydraulic
press.
Special tool
(A): 09913–75830
b) Install snap ring using snap ring pliers.
c) Apply grease to oil seal lip, install oil seal (2) to
coupling case (1) using special tool as shown in
figure.
NOTE
Install oil seal horizontally to surface of
coupling case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between case and oil seal “a”
: 1.5 – 2.5 mm (0.06 – 0.10 in.)
Special tool
(A): 09913–7581028) Install spacer (1) to coupling assembly (2) as shown
in figure.
29) Install grommet of coupling harness into groove of
coupling case and then install coupling assembly by
using hydraulic press.
30) Install companion flange to pinion, and then hold
companion flange with special tool and tighten flange
nut.
Tightening torque
Flange nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft)
Special tool
(A): 09930–40113
“A”
1
I5RW0A320058-02
(A)
I5RW0A320059-02
(A)
1 12, “A”“a”
I5RW0A320060-02
12
12
I5RW0A320065-01
(A)
I5RW0A320061-01

Downloaded from www.Manualslib.com manuals search engine 3B-47 Differential:
31) Clean mating surface of differential carrier (1) and
coupling case (2), apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate coupling case with
differential carrier as shown in figure, and then
tighten bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
NOTE
Install coupling pin (3) by fitting it to groove
(4) of coupling case.

32) Apply grease to oil seal lip, and then install oil seals
(1) to rear differential (2) using special tool as shown
in figure.
NOTE
Install oil seal horizontally to surface of rear
differential case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between rear differential and oil seal
“a”
: 1.0 – 2.0 mm (0.04 – 0.08 in.)
Special tool
(A): 09913–75810
33) Install drive shaft flange.
34) Install rear mounting bracket to rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
Rear Differential InspectionS6RW0D3206015
• Check companion flange for wear or damage.
• Check bearings for wear or discoloration.
• Check differential carrier for cracks.
• Check drive bevel pinion and bevel gear for wear or
cracks.
• Check side gears, pinion gears and pinion shaft for
wear or damage.
• Check side gear spline for wear or damage.
1 4
3 2“A”
(a)
I5RW0A320062-04
(A)
2 21, “A”
“a”
I5RW0A320063-02

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-48
Specifications
Tightening Torque SpecificationsS6RW0D3207001
NOTE
The specified tightening torque is also described in the following.
“Rear Differential Mountings Components”
“Rear Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D3208001
NOTE
Required service material is also described in the following.
“Rear Differential Components”

Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Differential oil level / filler plug 23 2.3 17.0) / )
Differential oil drain plug 23 2.3 17.0)
Coupling air temperature sensor 18 1.8 13.0)
Bevel gear bolt 73 7.3 52.0)
Bevel pinion nut 230 – 340 23.0 – 34.0 166.5 – 246.0)
Differential cover bolt 23 2.3 17.0)
Flange nut 110 11.0 79.5)
Coupling case bolt 23 2.3 17.0)
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) / ) / ) / ) / )

Downloaded from www.Manualslib.com manuals search engine 3B-49 Differential:
Special ToolS6RW0D3208002
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09912–34510 09913–50121
Case separator Oil seal remover
) / )) / )
09913–60910 09913–65135
Bearing and gear puller (40-
60mm)Bearing puller
))
09913–70123 09913–75510
Bearing installing tool Bearing installer
))
09913–75810 09913–75830
Bearing installer Steering pinion bush
installer
) / )) / )
09913–80113 09913–85210
Bearing installer Bearing installer
) / )) / ) / )
09922–76120 09922–76140
Mounting dummy shaft Bevel pinion shaft
) / )) / ) / )

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-50
09922–76150 09922–76250
Bevel pinion nut Bevel gear dummy
) / )) / )
09922–76330 09922–76340
Bevel pinion rear collar Bevel pinion rear collar
) / ) / )) / ) / )
09922–76420 09922–76530
Bevel pinion front collar Bevel pinion gauge block
) / ) / )) / )
09922–85811 09925–18011
Spring pin remover (4.5 mm) Transmission gear, bush
and bearing installer
) / ))
09925–88210 09926–48010
Bearing puller attachment Universal joint assembling
tool
) / )) / )
09927–27910 09930–40113
Holder, bevel pinion Flywheel rotor holder
) / )) / )
09951–26020 SUZUKI scan tool
Bush remover & installer
support—
) / )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. ) / )

Downloaded from www.Manualslib.com manuals search engine 3C-1 Transfer:
Driveline / Axle
Transfer
General Description
Transfer DescriptionS6RW0D3301001
The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in
transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction
drive gear, reduction driven gear and bevel gear of transfer. As bevel gears, which change the direction of driving
torque axis to the direction of the angle with 90 degrees, hypoid gears are provided. Hypoid gears have an advantage
of preventing gear noise, at the same time, they require accurate adjustment of tooth contact and backlash.
Diagnostic Information and Procedures
Transfer Symptom DiagnosisS6RW0D3304001
2
1
8
34
5
6
7
9
10I5RW0A330001-01
1. Intermediate shaft 5. Reduction driven gear 9. Transfer output retainer
2. Left case 6. Bevel gear 10. Transfer output flange
3. Reduction drive gear 7. Bevel pinion
4. Right case 8. Spacer
Condition Possible cause Correction / Reference Item
NoiseInadequate or insufficient lubricantReplenish.
Damaged or worn bearing(s)Replace.
Damaged or worn gear(s)Replace.
Preload of taper roller bearing is
reducedAdjust.

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-2
Repair Instructions
Transfer Oil Level CheckS6RW0D3306001
1) Lift up vehicle and check oil leakage. Repair leaky
point, if any.
2) Remove oil level / filler plug (1) and check oil
contamination and oil level is lower end of oil level /
filler plug hole (2).
If oil is excessive dirty or insufficient, replace oil or
pour specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transfer oil level / filler plug (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
Transfer Oil ChangeS6RW0D3306002
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) Check leakage.
If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain oil.5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transfer oil drain plug (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
6) Pour new specified oil up to lower end of oil level /
filler plug hole (3).
NOTE
It is highly recommended to use API GL-5
80W-90 gear oil.

Transfer oil specification
: API GL-5 (For SAE classification, refer to
viscosity chart [A] in figure.)
Transfer oil capacity
Reference: 0.6 liters (1.2/1.0 US/lmp. pt)
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transfer oil level / filler plug (b): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
I5RW0A330002-01
I5RW0A330003-01

Downloaded from www.Manualslib.com manuals search engine 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02