oil SUZUKI SWIFT 2000 1.G Transmission Service Manual PDF

TRANSFER 7D-3
ON-VEHICLE SERVICE
OIL CHANGE
1) Before changing or inspecting oil, be sure to stop engine and
lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage
exists, correct or repair it.
3) Drain old oil, tighten drain plug (3) after applying sealant to
its thread and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
“A” : Sealant 99000-31230
Tightening torque
Transfer oil drain plug (a) : 21 N·m (2.1 kg-m, 15.5 lb-ft)
Transfer gear oil
:Hypoid gear oil API GL-5
For oil viscosity, refer to the chart.
Oil Capacity
: 0.5 liters (1.1/0.9 US/lmp. pt)
4) Torque level/filler plug (4) as specified below after applying
sealant to its thread.
“A” : Sealant 99000-31230
Tightening torque
Transfer oil level / filler plug
(b) : 21 N·m (2.1 kg-m, 15.5 lb-ft) NOTE:
 It is highly recommended to use SAE 80W-90 Hypoid
gear oil API GL-5.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.
1. Transfer
2. Drive shaft

7D-4 TRANSFER
UNIT REPAIR OVERHAUL
1. Transfer left case 11. Bevel gear shim 21. Driven gear bearing
2. Transfer right case 12. Bevel gear (Hypoid gear) 22. Reduction drive gear bearing
3. Transfer output retainer 13. Bevel pinion shaft (Hypoid gear) 23. Flange nut
: After tightening nut so as rotation torque
of bevel pinion shaft to be in specified
value, caulk nut securely.
4. O-ring
: Apply grease 99000-25010 to all
around surface14. Reduction driven gear 24. Stiffener
5. Bevel pinion shim 15. Flange 25. Intermediate right bearing
6. Drain plug
: Apply sealant 99000-31230 to all
around thread part of drain plug16. Pinion shaft spacer Do not reuse.
7. Level plug
: Apply sealant 99000-31230 to all
around thread part of level plug17. Reduction drive gear Tightening torque
8. Intermediate shaft 18. Circlip Apply transfer oil.
9. Oil seal
: Apply SUZUKI SUPER GREASE A
99000-25010 to oil seal lip.19. Snap ring
10. Pinion shaft bearing 20. Bevel gear nut
: After tightening nut to specified
torque, caulk nut securely

TRANSFER 7D-5
UNIT DISMOUNTING
1) Disconnect negative cable at battery.
2) Hoist vehicle and remove wheels.
3) Drain transmission oil.
4) Remove exhaust No.1 pipe (1).
5) Remove propeller shaft.
6) Remove right side drive shaft (1) refer to Section 4A.
7) Remove Stiffener (3).
8) With transmission assembly held on jack, remove rear
mounting bolts (1).
9) Remove transfer mounting bolts and draw out transfer
assembly from transmission assembly.
2. Exhaust No.2 pipe
12
1
1. Transfer
2. Transmission
1

7D-8 TRANSFER
5) Remove driven gear bearing outer race from left case (1) by
using special tool.
Special tool
(A) : 09941-54911
6) Remove driven gear bearing outer race from right case (1)
by using special tool.
Special tool
(A) : 09941-54911
INTERMEDIATE SHAFT
1) Remove reduction drive oil seal and snap ring, and then
drive out intermediate shaft.
2) Drive out intermediate right bearing (1) from intermediate
shaft by using bearing puller and press.
3) Remove intermediate center oil seals (1) by using press and
special tools.
Special tool
(A) : 09924-84510-005
(B) : 09913-75821

TRANSFER 7D-9
TRANSFER OUTPUT RETAINER
1) Uncaulk flange nut.
2) Remove flange nut while holding flange (2) by using special
tool.
Special tool
(A) : 09930-40113
3) Remove flange (1) by special tool.
Special tool
(A) : 09913-65135
4) Drive out bevel pinion shaft from transfer output retainer by
tapping with plastic hammer.
5) Drive out pinion spacer from bevel pinion shaft.
6) Drive out pinion shaft bearing (2) from bevel pinion shaft (1)
by using press.
7) Remove pinion shaft oil seal (1) by using special tool.
Special tool
(A) : 09913-50121
1. Power wrench
3. Bearing puller

7D-10 TRANSFER
8) Drive out pinion shaft bearing outer races (2) (front and rear)
by using brass bar (1).
COMPONENT INSPECTION
Check each bearing for smooth rotation, wear or discolora-
tion.
If found abnormal, replace.
Check oil seal for leakage and its lip for excessive hardness.
If either is found, replace.
Check transfer case for cracks.
Check bevel pinion and bevel gear for wear or cracks.
Check pinion gear and pinon shaft for wear or damage.
UNIT ASSEMBLY
Judging from faulty conditions noted before disassembly and
what is found through visual check of bearing and gear tooth etc.
after disassembly, prepare replacing parts and proceed to reas-
sembly according to procedures as described below.
REDUCTION DRIVEN GEAR
1) Drive in bevel gear to reduction driven gear.
2) Tighten bevel gear nut to specified torque while holding
bevel gear with soft jawed vise and caulk (1) nut.
Tightening torque
Transfer bevel gear nut
(a) : 150 N·m (15.0 kg-m, 108.5 lb-ft)
CAUTION:
 Bevel gear and pinion must be replaced as a set when
either replacement becomes necessary.
 When replacing taper roller bearing, replace as inner
race & outer race assembly.

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

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