1987 SUZUKI GRAND VITARA Service Repair Manual

14-1. GENERAL DESCRIPTION
The transfer gear box is an auxiliary transmission for on-off control of two-speed drive transmitted to
both front and rear axles concurrently and provides additional speed reductions, HIGH and LOW, for any
selection of main transmission gears.
The functions of this auxiliary transmission are mainly two-selection between four-wheel drive (front and
rear axles) and two-wheel drive (rear axle) and between HIGH and LOW for four-wheel drive. Three
propeller shafts are associated with the gear box.
These functions are accomplished by means of four shafts arranged in three-axis configuration and two
sliding clutches. The selection is effected by actuating these clutches from a single control lever located
beside the driver’s seat. The gear box is mounted on a chassis frame.
1.Flange
2.Oil seal
3.Circlip
4.Bearing
5.Nut6.Input shaft
7.Bearing
8.Counter shaft lock plate
9.O-ring
10.Counter shaft
11.Bearing
12.Spacer
13.Thrust washer
14.Counter gear
15.Flange
16.Oil seal
17.Circlip
18.Bearing
19.Output front shaft
20.Bearing
21.Circlip
22.Sleeve
23.Hub
24.Bearing
25.Thrust washer
26.Bearing
27.Output high gear
28.Sleeve
29.Output rear shaft
30.Output low gear
31.Bearing
32.Speedometer drive gear
33.Bearing
34.Retainer
35.Oil seal
36.Speedometer driven gear
37.Speedometer gear case
38.Oil seal
39.Shim
40.Flange
41.Washer
Fig. 14- 1
14-2
Fig. 14-1

14-2. SELECTIVE FLOWS OF TRANSFER DRIVE
2-Wheel Drive (Rear-Wheel Drive)
Rear shifter fork pushes rear clutch sleeve into
“high” gear, thus coupling the gear to output
rear shaft.
Drive flows from input shaft to output rear shafttra”SmiSSion
through big gear, “high” gear and rear clutch.
Gear shift control lever position
a-wheel drive
(Rear wheel drive)
Fig. 14-2
4-Wheel Drive HIGH (All-Wheel Drive on HIGH)
Under the conditions of rear-wheel drive,
described above, front shifter fork pushes the
sleeve of front clutch onto the toothed clutch From .
ring, thus coupling output rear shaft to output transm’ss’on
shaft runefront shaft. Front shaft and rear
together on HIGH.
Gear shift control lever position
4-wheeldrive HIGH
To front wheel
Fig. 14-314-3

4-Wheel Drive LOW (All-Wheel Drive on LOW)
Gear shift control lever position
4-wheeldrive LOW
2H
5l
Front shifterforkactuates front clutch to couple
rear shaft to front shaft; and rear shifter fork
actuates rear clutch to couple “low” gear to rear
shaft. Front shaft and rear shaft run together on From
LOW.
To front whe
Fig. 14-4
14-3. GEAR RATIO DATA
Gear
Reduction
Rear-wheel drive
41/44 - 62/41
1.409
All-wheel drive high
41/44 62/41-
1.409
All-wheel drive low
41/44 - 56/23
2.268
14-4

14-4. TRANSFER SERVICES NOT REQUIRING TRANSFER REMOVAL
Following parts or components do not require transfer removal to receive services (replacement, inspec-
tion) :
Part or ComponentNature of Service
1. Universal-joint yoke flangesReplacement or inspection
2. Front drive shift shaft forkReplacement or inspectionI
3. Transfer output front shaft oil seal
4. Transfer output front shaft bearing
5. Transfer output front shaft
Replacement or inspection
Replacement
Replacement
6. Transfer front caseReplacement
7. Front drive clutch hubReplacement or inspection
8. Front drive clutch sleeveReplacement or inspection
9. Transfer input shaft oil sealReplacement
10. 4WD indicator light switchReplacement or inspection
11. Speedometer driven gearReplacement or inspection
12. Gear shift control leverReplacement or inspection
13. Gear shift control boot No. 1, No. 2Replacement
14. Gear shift control lever spring seatReplacement or inspection.
14-5

14-5. REMOVAL
1) Lift up car and remove securing bolts from
each universal-joint flange connection to
sever 3 propeller shafts from transfer gear
box.
Fig. 14-5
2) Remove clamp @ and boot @ from transfer
gear box.
Fig. 14-7
4) Drain out oil from gear box by loosening
its drainplug.
Fig. 14-8
5) Disconnect speedometer drive cable from
transfer gear box.
Transfer‘gear case
Fig. 14-6
3) Twist control lever guide counterclockwise
while pushing it down; this will permit lever
to be removed from gear box.
14-6
Fig. 14-8
Fig. 14-9

6) Disconnect 4WD switch lead wire at coupler.
7) Remove 3 mounting nuts securing gear box
to chassis, and take down gear box.

14-7
Fig. 14-11

14-6. DISASSEMBLY
Universal-Joint Yoke Flanges
There are 3 flanges to be removed: one from
input shaft and other from output front and rear
shafts. Lock flange so that it will not turn, and
loosen and remove nut holding flange to the
shaft. Draw off flange.
Fig. 14-12 @ Special tool (09930401131
Speedometer Driven Gear
Loosen speedometerdriven gear case bolt
and remove speedometer driven gear case with
gear.
Transfer Front Case
Remove the indicator light switch from front
case.
NOTE:
Use care not to lose switch ball. This ball is
larger than interlock ball and locating balls.
Fig. 14-16
Remove bolts securing transfer front case,
and take off case.
By tapping output front shaft with a plastic
hammer,remove output front shaft from
front case.
Fig. 14-18
Fig. 14-15
14-8
Fig. 14-17

After removing oil seal, remove circlip and drive
bearing out of front case by using bearing
installer (special tool).
Bearing installer 0 : (09913-76010)
Fig. 14-19
Transfer Center Case
Remove bolts fastening center case and rear
case together.
Do not loosen bolt @ at this point.
By tapping rear case and output rear shaft with.
a plastic hammer, separate center and rear case.
Fig. 14-22
Given below are procedures for disassembling
component parts of center case as separted from
rear case.
1) Loosen gear shift locating spring plug and
take out spring and locating ball.
Fig. 14-23
14-9
Fig. 14-20
Fig. 14-21