torque SUZUKI SX4 2006 1.G Service Workshop Manual

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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 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.

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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

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• Pour transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change in Section 5B” and “Transfer Oil
Change”.
Transfer Assembly ComponentsS6RW0D3306004
1
2
6
9
1110
8
7
3A
4
5
36
OIL
(a) 5
(a)
OIL
28
18
30
27
25
21
28
13
12
22OIL
OIL
32A
31A
1322(d)
34A
33
23A
2019
(c)1217G
291217G
(b)
35
15A
26
26 14
24
17
161217G(b)
A
I5RW0A330007-05
1. Transfer output flange nut
: After tightening nut so as rotational torque
of bevel pinion to be in specified value,
caulk nut securely.15. Dowel pin 29. Transfer right case
: Apply sealant 99000-31260 to
mating surface with right case.
2. Transfer output flange 16. Oil drain plug
: Apply sealant 99000-31260 to thread
part.30. Oil level / filler plug
: Apply sealant 99000-31260 to
thread part.
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.17. Transfer left case
: Apply grease 99000-25010 to left case.31. Left case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
4. Pinion shaft rear taper roller bearing 18. Transfer case bolt 32. Left case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
5. Transfer output retainer bolt 19. Reduction drive gear left bearing 33. Right case oil seal No.3
: Apply grease 99000-25010 to oil
seal lip.
6. O-ring
: Apply grease 99000-25010 to all around
surface.20. Reduction drive gear 34. Right case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
7. Shim 21. Reduction driven gear left taper roller
bearing35. Right case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
8. Spacer 22. Reduction driven gear right taper roller
bearing36. Transfer output retainer

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d) Select a shim which is close to half thickness of
the calculated value (necessary shim thickness)
from among the available shims to install it
between bearing and case at each of right and
left sides.
For example:
Measure distance “a” is 110.75 mm (4.360 in.).
Measure depth “b” is 85.8 mm (3.378 in.).
Measure depth “c” is 26.55 mm (1.045 in.).
Necessary shim thickness = 85.8 mm (3.378 in.)
+ 26.55 mm (1.045 in.) – 110.75 mm (4.360 in.) +
0.1 mm (0.004 in.) = 1.7 mm (0.067 in.)
1.7 mm (0.067 in.) ÷ 2 = 0.85 mm (0.033 in.)
Calculated thickness of new shim = 0.85 mm
(0.033 in.)
Available reduction driven gear shim
thickness
0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95,
1.00 and 1.05 mm (0.024, 0.026, 0.028, 0.030,
0.031, 0.033, 0.035, 0.037, 0.039 and 0.041 in.)
2) Clean mating surface of right and left cases, and
apply sealant to right case (1) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
3) Assemble the following parts in right and left cases
by reversing disassembling procedure.
• Reduction drive gear assembly (1)
• Reduction driven gear assembly (3)
• Bearing outer races (2)
• Reduction driven gear shims (5)
• Dowel pin (6)
4) Tighten transfer case bolts (4) to specified torque.
Tightening torque
Transfer case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)5) Select bevel pinion shim (3) referring to step 1) of
“Reassembly” under “Transfer Output Retainer
Assembly Disassembly and Reassembly”.
6) Inspect tooth contact according to “Bevel Gear Tooth
Contact Inspection”.
7) Install transfer output retainer assembly (2) with
bevel pinion shim (3) to transfer left case (4) by
tightening retainer bolt (1) to specified torque.
Tightening torque
Transfer output retainer bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)
8) Install bolt to bolt hole of flange (2), set dial gauge
measuring tip at right angles to bolt (1) as shown in
figure. Holding reduction driven gear by hand, take
measurement backlash of pinion and bevel gear.
NOTE
If backlash exceeds specification given
below, adjust it by changing thickness ratio
of shims assembled in right and left cases in
Step 3).

Special tool
(A): 09900–20607
(B): 09900–20701
Bevel pinion & bevel gear backlash
: 0.1 – 0.2 mm (0.0039 – 0.0078 in.)
1
“A”
I5RW0A330011-01
6
4, (a) 5 2
31
2
5
I5RW0A330012-02
4
3
21, (a)
1, (a)
I5RW0A330013-02
(A)
1
(B)
2
I5RW0A330014-02

Downloaded from www.Manualslib.com manuals search engine 3C-9 Transfer:
3) Install left bearing (1) to reduction driven gear (2)
using special tools and hydraulic press.
Special tool
(A): 09913–84510
(B): 09924–84510–005
Transfer Right Case and Left Case Disassembly
and Reassembly
S6RW0D3306008
Disassembly
1) Remove oil seals from right case (1) using special
tool, if necessary.
Special tool
(A): 09925–15410
2) Remove oil plate (1) from right case (2), if necessary.
3) Remove oil seals from left case using flat end rod or
the like, if necessary.Reassembly
1) When installing oil seal No.2 (1) and No.3 (2) to right
case (3) using special tool, use care so that oil seals
in proper direction and position as shown in figure.
Apply grease to oil seal lip.
Special tool
(A): 09925–15410
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Oil seals installing depth
“a”: 23.5 – 24.0 mm (0.925 – 0.945 in.)
“b”: 38.0 – 39.0 mm (1.496 – 1.535 in.)
2) Install oil plate to right case.
Tightening torque
Oil plate bolt: 9 N·m (0.9 kgf-m, 6.5 lb-ft)
3) When installing new oil seal No.1 (1) and No.2 (2) to
left case (3) using special tool, use care so that oil
seals in proper direction as shown in figure.
Apply grease to oil seal lip.
Special tool
(A): 09913–85210 (For oil seal No.1)
(A): 09944–88210 (For oil seal No.2)
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
(A)
1
2
(B)I5RW0A330025-02
(A)
1
I5RW0A330026-01
1
2
I5RW0A330027-01
1, “A”
2, “A”“a”
(A)
3 “b”
I5RW0A330028-01
3
(A)
2, “A”1, “A”I5RW0A330029-01

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c) Tighten bevel pinion nut (special tool) so that
specified bearing preload is obtained.
NOTE
Before taking measurement, check for
rotation by hand more than 15 revolutions.

Tightening torque
Rotational torque of bevel pinion (Bearing
preload): 0.50 – 1.30 N·m (0.05 – 0.13 kgf-m,
0.35 – 0.95 lb-ft)
d) Measure height “b” in figure by using vernier
caliper.
Calculate “c” by using measured value.e) Obtain adjusting shim thickness by the following
equation.
f) Select a shim closest to the calculated value
(necessary shim thickness) from among the
available shims or combine shims to become
closest to calculated value.
For example:
Measure distance “b” is 69.95 mm (2.754 in.).
“c” = 69.95 mm (2.754 in.) – 40.0 mm (1.757 in.)
= 29.95 mm (1.179 in.)
“f” = 29.95 mm (1.179 in.) + 74.0 mm (2.913 in.)
– 101.95 mm (4.014 in.) = 2.0 mm (0.079 in.)
Calculated thickness of new shim = 2.0 mm
(0.079 in.)
Available bevel pinion shim thickness
0.30, 1.85, 1.88, 1.91, 1.94, 1.97, 2.00, 2.03,
2.06, 2.09, 2.12 and 2.15 mm (0.012, 0.072,
0.074, 0.075, 0.076, 0.077, 0.078, 0.079, 0.081,
0.082, 0.083 and 0.084 in.) Distance “c” = Height “b” –Height “a” 40 mm
(1.575 in.)
I5RW0A330036-02
“a”
“b”
“c”
I5RW0A330046-01
Necessary
shim
thickness “f”=Distance
“c”+Distance
“d”
–Distance
“e”
74.0 mm
(2.913 in.)101.95 mm
(4.014 in.)
“d”: Pinion shaft mounting distance 74.0 mm (2.913 in.)
“e”: Distance from end face of left case to axis of reduction driven gear
101.95 mm (4.014 in.)
“f”: Necessary shim thickness
“d” “e”
“f ”
I5RW0A330037-01

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8) Install transfer output flange (1) by tapping with
plastic hammer and tighten transfer output flange nut
gradually so as rotational torque of bevel pinion to be
in specified value.
NOTE
• If rotational torque of bevel pinion exceeds
specification given in the following,
replace pinion shaft spacers and tighten
flange nut.
• Before taking measurement of rotational
torque, rotate pinion over ten rounds in
advance.

Bevel pinion bearing preload
: 0.5 – 1.3 N⋅m (0.05 – 0.13 kgf-m, 0.35 – 0.95 lb-ft)
Special tool
(A): 09930–40113
9) Caulk transfer output flange nut (1).
Transfer Assembly InspectionS6RW0D3306010
• Check each bearing for smooth rotation, wear or
discoloration
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 gears for wear or
cracks.
Bevel Gear Tooth Contact InspectionS6RW0D3306011
1) After cleaning tooth surface of bevel gear (1), paint
them with gear marking compound evenly by using
brush or sponge etc.
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.

2) Install transfer output retainer assembly referring to
“Transfer Assembly Disassembly and Reassembly”.
3) Turn transfer output flange clockwise and
counterclockwise repeatedly, and remove transfer
output retainer assembly and bevel gear shims from
transfer assembly.
2. Torque wrench
(A)1
2
I5RW0A330043-01
1
I5RW0A330044-01
I3RH01332043-01

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Specifications
Tightening Torque SpecificationsS6RW0D3307001
NOTE
The specified tightening torque is also described in the following.
“Transfer Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. 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 remedy
is to replace the pinion and gear set and, if the seat is
defective, so is transfer case. Tooth contact pattern Diagnosis and remedy
I3RH01332048-01
I3RH01332049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transfer oil level / filler plug 23 2.3 17.0) / )
Transfer oil drain plug 23 2.3 17.0)
Stiffener No.1 bolt and No.2 bolt 55 5.5 40.0)
Transfer to transaxle bolt 98 9.8 71.0)
Transfer case bolt 23 2.3 17.0)
Transfer output retainer bolt 55 5.5 40.0)
Oil plate bolt 9 0.9 6.5)
Rotational torque of bevel pinion (Bearing
preload)0.50 – 1.30 0.05 – 0.13 0.35 – 0.95)