SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-4
• 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

Downloaded from www.Manualslib.com manuals search engine 3C-5 Transfer:
Transfer Assembly Disassembly and
Reassembly
S6RW0D3306005
Disassembly
NOTE
It is possible to disassemble transfer
assembly without removing intermediate
shaft with Step 1) to 4) performed if not
necessary.

1) Remove right case oil seal No.1 (1) from transfer
right case using special tool.
Special tool
: 09913–50121
2) Remove snap ring (2) by using snap ring pliers.
3) Remove intermediate shaft (4) with intermediate
shaft bearing (3) from transfer assembly.
4) Remove intermediate shaft bearing (3) from
intermediate shaft (4) by using bearing puller and
hydraulic press.
5) Remove transfer output retainer assembly (1) and
shim (3) by removing retainer bolts (2).
6) Remove transfer case bolts (4).
7) Separate transfer right case (5) from transfer left
case (6) by using special tool.
Special tool
(A): 09912–34510
8) Remove reduction drive gear assembly (7) and
reduction driven gear assembly (9).
9) Remove shim (10) and bearing outer races (8).
NOTE
When it is difficult to remove bearing outer
races from cases, remove them with special
tool.

Special tool
(B): 09944–96011Reassembly
1) Select appropriate shim as follows.
a) Measure distance “a” between taper roller
bearing outer races of reduction driven gear
assembly (1).
b) Measure depth “b” of left case (2) and “c” of right
case (3).
c) Obtain adjusting shim thickness by the following
equation.
9. Pump seal 23. Reduction drive gear right bearing : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
10. Pinion shaft front taper roller bearing 24. Intermediate shaft : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
11. Bevel pinion 25. Oil protect plate bolt
: Apply thread lock cement 99000-32110
to thread part.: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
12. Bevel gear 26. Snap ring : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
13. Reduction driven gear 27. Oil protect plate : Do not reuse.
14. Intermediate shaft bearing 28. Shim : Apply transfer oil.
4
3
2
1
I5RW0A330008-01
11. Dowel pin
Necessary
shim
thickness=Depth
“b”+Depth
“c”–Distanc
e “a”+0.1 mm
(0.004
in.)
7
(B)
5
11
310 9 10
8 64
8
(A)
12
2
I5RW0A330009-03
23
1
“b”
“a”“c”
I5RW0A330010-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-6
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-7 Transfer:
9) Install intermediate shaft bearing (1) to intermediate
shaft (2) by using special tool.
Special tool
(A): 09913–84510
10) Install intermediate shaft (2) with bearing (3) in
transfer.
11) Install new snap ring (1) to transfer right case by
using snap ring pliers.
12) Apply grease to new right case oil seal No.1 lip.
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
13) Drive right case oil seal No.1 (1) in transfer right
case (2) by using special tool and hammer.
Special tool
(A): 09925–15410
Intermediate output oil seal installing depth
“a”: 1.0 – 1.5 mm (0.04 – 0.06 in.)
Reduction Drive Gear Assembly Disassembly
and Reassembly
S6RW0D3306006
Disassembly
Remove bearings (1) from reduction drive gear (2) using
special tool, bearing puller (3) and hydraulic press (4).
Special tool
(A): 09913–85230
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one as
necessary.
2) Install bearings (1) to reduction drive gear (2) using
special tool, bearing puller (3) and hydraulic press
(4).
Special tool
(A): 09913–85230
(A)
1
2
I5RW0A330015-01
132
I5RW0A330016-02
(A)
1, “A”
2
2
“a”
I5RW0A330017-02
4
(A)2
1
3I5RW0A330018-01
(A)
2
4
1
3I5RW0A330019-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-8
Reduction Driven Gear Assembly Disassembly
and Reassembly
S6RW0D3306007
Disassembly
1) Remove left bearing (1) and bevel gear (2) using
special tool, bearing puller (3) and hydraulic press
(4).
Special tool
(A): 09925–98221
2) In order to remove right bearing (1) from reduction
driven gear (2), grind with a grinder (3) one part “a”
of bearing as illustrated till it becomes thin.
CAUTION!
Be careful not to grind too far not to damage
reduction driven gear.

3) Break with a chisel (1) the thin ground bearing (2),
and it can be removed.Reassembly
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 and outer race
assembly.

1) Install right bearing (1) to reduction driven gear (2)
using special tools and hydraulic press.
Special tool
(A): 09924–74510
(B): 09925–16310
2) Install bevel gear (1) to reduction driven gear (2)
using special tools and hydraulic press.
Special tool
(A): 09924–07710
(B): 09924–84510–005
(C): 09925–154104
(A)1
23
I5RW0A330020-02
1
2
3
1
2“a”
I5RW0A330021-01
1
2I5RW0A330022-01
(A)
(B)
1
2
I5RW0A330023-01
(C)
(A)
2
1
(B)
I5RW0A330024-01

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

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-10
Transfer Output Retainer Assembly
Disassembly and Reassembly
S6RW0D3306009
Disassembly
1) Uncaulk transfer output flange nut.
2) Remove transfer output flange nut while holding
flange (1) by using special tool.
Special tool
(A): 09930–40113
3) Remove transfer output flange (1) by bearing puller
(2).
4) Drive out bevel pinion (1) from transfer output
retainer by tapping it with plastic hammer (2).5) Drive out front taper roller bearing (1) from bevel
pinion (3) by using bearing puller (2) and hydraulic
press.
6) Remove oil seal (1) by using special tool.
Special tool
(A): 09913–50121
7) Remove rear taper roller bearing (1), pump seal (3)
and spacers (2).
8) Drive out outer races (2) (front and rear) by using
brass bar (1).
(A)
1
I5RW0A330030-01
2
1
I5RW0A330031-01
1 2
I3RH01332019-01
3
12
I5RW0A330032-01
1(A)
I3RH01332020-01
1
2
3
I5RW0A330033-03
11
2
2I5RW0A330034-01

Downloaded from www.Manualslib.com manuals search engine 3C-11 Transfer:
Reassembly
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 and outer race
assembly.

1) To mesh bevel gears correctly, it is prerequired to
install bevel pinion to transfer output retainer
properly by using adjusting shim (bevel pinion shim)
as follows.
a) Install front taper roller bearing (1) to bevel pinion
dummy (special tools).
Special tool
(A): 09922–76140
(B): 09922–76430b) Install bevel pinion dummy (1), rear taper roller
bearing (2) and special tools to transfer output
retainer (3).
Special tool
(A): 09922–76140
(B): 09922–76430
(C): 09922–76340
(D): 09922–76150
NOTE
This installation requires no spacer or oil
seal.

I3RH01332053-01
“a”: Pinion dummy height 40 mm (1.575 in.)
“b”: Height from retainer installation face to top surface of pinion dummy
“c”: Distance from retainer installation face to end face of bearing race
(A)
(B)
1
3
2
(C)
(D)
“a”
“b”
“c”
I5RW0A330035-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-12
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

Downloaded from www.Manualslib.com manuals search engine 3C-13 Transfer:
2) Press-fit outer races (front and rear) by using special
tool and hydraulic press.
Special tool
(A): 09913–75520
3) Press-fit front taper roller bearing (1) by using
special tool and hydraulic press.
Special tool
(A): 09925–18011
4) Install bevel pinion with new pinion shaft spacers (1)
and new pump seal (2) to transfer output retainer (3).5) Drive in rear taper roller bearing by using special tool
and tapping lightly with plastic hammer.
Special tool
(A): 09913–84510
6) Apply grease to new oil seal lip.
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
7) Drive in oil seal (1) by using special tools and
hammer.
Special tool
(A): 09940–54910
(B): 09913–76010
Transfer output flange oil seal installing depth
“a”: 21.0 – 22.0 mm (0.82 – 0.86 in.)
(A)
I5RW0A330038-01
(A)
1
I5RW0A330039-01
1
2
3
I5RW0A330040-02
(A)
I5RW0A330041-02
(B)
(A)
1, “A”
“a”
I5RW0A330042-02