2006 SUZUKI GRAND VITARA transfer case

3-16
OPERATING YOUR VEHICLE
79K21-03E
64J143
(2)
(5)
(3)
(4)
(7)
(9)
(6)
(1)
(11)
(10)
(8)
(1) Front differential
(2) Engine
(3) Transmission
(4) High/Low clutch
(5) Transfer case
(6) Center differential
(7) Differential lock clutch
(8) Chain
(9) Rear propeller shaft
(10) Rear differential
(11) Front propeller shaft
Using the Transfer Switch: 10
Braking: 6

3-22
OPERATING YOUR VEHICLE
79K21-03E
NOTE:
The information display shows the warning
and indicator message when the transfer
system is operated, or has a problem.
CAUTION
 Be sure to stop the vehicle com-
pletely before operating the trans-
fer switch to shift between “N” and
“4H”, or between “4H LOCK” and
“4L LOCK”.
 Do not shift between “4H” and “4H
LOCK” unless the front wheels are
in the straight-ahead position and
we recommend that the vehicle
speed be less than 100 km/h (60
mph).
Do not operate the transfer switch
while tires are racing.
 Do not operate your vehicle in “4H
LOCK” or “4L LOCK” on dry, hard
surfaces.
(Continued)
CAUTION
(Continued)
 Do not operate the vehicle while a
4WD mode indicator is blinking
except when shifting between “4H”
and “4L LOCK”.
If you operate the vehicle while a
4WD mode indicator is blinking, a
buzzer will sound and the transfer
will shift to “N” (Neutral) to prevent
transfer case damage.
In this case, use the following pro-
cedure.
1) Release your foot from the accel-
erator pedal and depress the
brake pedal to stop the vehicle
completely.
2) Depress the clutch pedal fully (if
equipped) or shift the automatic
transmission gearshift lever to the
“N” position.
3) If the transfer does not shift from
“N” although you perform 1) and
2), turn the transfer switch to the
position previously selected and
operate the switch again.
Catalytic Converter: NO

4-6
DRIVING TIPS
79K21-03E
Off-Road DrivingYour vehicle has specific design character-
istics for off-road driving. When you leave
the pavement, you will encounter driving
surfaces of all kinds which may change
continually as you drive. In most cases, off-
road driving requires the use of 4-wheel
drive. If your vehicle is a 2-wheel drive
vehicle, you should limit your off-road driv-
ing only to hard, flat, nonslippery surfaces.
2-wheel drive vehicles have far less trac-
tion on off-road surfaces than 4-wheel
drive vehicles. It is important when driving
off-road to follow the guidelines below.
Use Caution on Steep Inclines
Always inspect hills before you attempt to
drive up them. Know what is on the other
side and how you will get back down. If you
have any doubt that it is safe, do not
attempt to drive over a hill. Never drive
your vehicle up an extremely steep incline.
Coming down a steep hill can be trickier
than getting up one. Keep the vehicle
heading straight down the hill and use low
gear. Do not lock the brakes. If the vehicle
begins to slide, accelerate slightly to regain
steering control.Do Not Turn on or Drive Across the Side
of Hills
Turning on or driving across the side of a
hill can be extremely hazardous. Most of
the vehicle’s weight will be transferred to
the downhill tires, which could result in the
vehicle rolling sideways. Whenever possi-
ble, avoid this potential hazard. Also, if you
have to exit your vehicle on a side-hill,
always get out on the uphill side.
Wear Your Seat Belts at All Times
You and your passengers should use the
seat belts at all times when driving off-
road. For proper seat belt use, refer to the
“Seat Belts and Child Restraint Systems”
section in this manual.
Avoid Sudden Reactions in Mud, Ice or
Snow
Be careful when off-road conditions are
slick. Reduce your speed and avoid sud-
den movements of the vehicle. If your vehi-
cle is a 2-wheel drive vehicle, do not drive
in deep snow or mud. If your vehicle is a 4-
wheel drive vehicle, be aware that driving
in deep snow or mud can cause a loss of
traction and an increase in the resistance
to the vehicle’s forward motion. Use 4WD
low gear (4L) and maintain a steady but
moderate speed with a light touch on the
steering wheel and brakes.Do not drive in the field covered with
grown grass
If you drive in the field covered with grass,
it may cause unexpected accident or vehi-
cle damage by getting caught in grown
grass.
If Your Vehicle Gets Stuck
If your vehicle gets stuck in snow, mud or
sand, follow the directions below:
1) (For vehicles equipped with transfer
switch) Turn the transfer switch to “4H
LOCK” or “4L LOCK”.
2) Shift the transmission back and forth
between a forward range (or first gear
for manual transmission) and reverse.
This will create a rocking motion which
may give you enough momentum to
free the vehicle. Press gently on the
accelerator to keep wheel spin to a min-
imum. Remove your foot from the
accelerator while shifting.
Do not race the engine. Excessive
wheel spin will cause the tires to dig
deeper, making it more difficult to free
the vehicle.
3) If your vehicle remains stuck after a few
minutes of rocking, get another vehicle
to pull you out.

4-7DRIVING TIPS
79K21-03E
Tire ChainsTire chains should only be used if they are
needed to increase traction or are required
by law. Make sure that the chains you use
are small-link chains or cable-type chains
and are the correct size for your vehicle’s
tires. Also make sure that there is enough
clearance between the fenders and the
chains as installed on the tires.
Install the chains on the rear tires tightly,
according to the chain manufacturer’s
instructions. Retighten the chains after
driving about 1.0 km (1/2 mile) if neces-
sary. With the chains installed, drive slowly.Do not drive through deep or rushing
water
Driving in deep or rushing water can be
hazardous. You could lose control of the
vehicle and the occupants could drown.
Also, your vehicle could be seriously dam-
aged. To avoid these risks, observe the fol-
lowing instructions and precautions.
 Do not drive through deep or rushing
water. Deep or rushing water, such as
fast-moving streams or floodwaters,
could carry your vehicle away from your
intended path. The water is too deep if it
covers your wheel hubs, axles or
exhaust tailpipe. Know the depth of the
water before you attempt to drive
through it.
 If water blocks the tailpipe, the engine
may not start or run. If the water is deep
enough to get drawn into the engine
intake system, the engine will be badly
damaged.
 Submerged brakes will have poor brak-
ing performance. Drive slowly and care-
fully. Driving slowly will also help avoid
water splashing onto the ignition system,
which could cause the engine to stall.
 Even when driving through shallow or
still waters, drive carefully since the
water may be hiding ground hazards
such as holes, ditches or bumps.
WARNING
 Do not allow anyone to stand near
the vehicle when you are rocking it,
and do not spin the wheels faster
than an indicated 40 km/h (25 mph)
on the speedometer. Personal
injury and/or vehicle damage may
result from spinning the wheels too
fast.
 Be sure to turn the transfer switch
from “4H” to “4H LOCK” or “4L
LOCK” when the tires slip in “4H”.
The continuing tires slip in “4H”
can cause the limited slip differen-
tial gear damage in the center dif-
ferential.
CAUTION
Release the accelerator pedal when
operating the gearshift lever. Operat-
ing the lever with the engine racing
can damage the gears.
CAUTION
Do not continue rocking the vehicle
for more than a few minutes. Pro-
longed rocking can cause engine
overheating, transmission or trans-
fer case damage or tire damage.
CAUTION
If you hear the chains hitting against
the vehicle body while driving, stop
and tighten them.

6-9VEHICLE LOADING AND TOWING
79K21-03E
7) Release the parking brake.
Stop towing the vehicle every 300 km (200
miles). Start the engine. With the manual
transmission lever in 2nd gear (or the auto-
matic transmission lever in “D”) and the
transfer switch in neutral, rev the engine for
about one minute with the clutch engaged
(if equipped), to circulate oil in the transfer
case.
64J148
TOWING METHOD AFOUR WHEELS ON THE GROUND
Towing Your Vehicle (recreational towing): 13

7-17INSPECTION AND MAINTENANCE
79K21-03E
65D434
You should inspect spark plugs periodically
for carbon deposits. When carbon accu-
mulates on a spark plug, a strong spark
may not be produced. Remove carbon
deposits with a wire or pin and adjust the
spark plug gap.
To access the spark plugs:
1) Remove the engine cover.
2) Disconnect the coupler (1) while push-
ing the release lever.
3) Remove the bolt.
4) Pull the ignition coil out.
80G093
Gear OilSpecified Gear OilWhen replacing gear oil, use gear oil with
the appropriate viscosity and grade as
shown in the charts below. We highly rec-
ommend you use SAE 75W-90 gear oil
(SAE 80W-90 for front differential oil, rear
differential oil and transfer gear oil).
Transmission/Extension case
54G095
Differential/Transfer case
65D594
CAUTION
When replacing spark plugs, you
should use the brand and type speci-
fied for your vehicle. For the speci-
fied plugs, refer to the
“SPECIFICATIONS” section at the
end of this book. If you wish to use a
brand of spark plug other than the
specified plugs, consult your SUZUKI
dealer.1.0 – 1.1 mm
(0.039 – 0.043 in.)
Engine Coolant: 1, 2
Windshield Washer Fluid: 3

7-18
INSPECTION AND MAINTENANCE
79K21-03E
Manual transmission
52D087
Transfer case
66J005
(1) Oil filler and level plug
(2) Oil drain plugExtension case (2WD)
66J165
(1) Oil filler and level plug
(2) Oil drain plug API GRADE
Transmission/
Extension caseGL-4
Transfer case
GL-5
(Hypoid gear oil)
DifferentialFront
Rear
(1)
(2)
(2)(1)
Windshield Washer Fluid: 3
Air Cleaner: 1, 2

7-19INSPECTION AND MAINTENANCE
79K21-03E
Front differential
79K133
Rear differential
79K134
(1) Oil filler and level plug
(2) Oil drain plug
Gear Oil Level CheckThe manual transmission, transfer gears,
extension case and differentials (front and
rear) are lubricated with gear oil. To check
the gear oil level in any of the above loca-
tions, use the following procedure:
1) Park the vehicle on a level surface. Set
parking brake and stop the engine.
2) Remove the oil filler plug (1).
3) Check the inside of the hole with your
finger. If the oil level comes up to the
bottom of the plug hole, the oil level is
correct. If so, reinstall the plug.
4) If the oil level is low, add gear oil
through the filler plug hole (1) until the
oil level reaches the bottom of the filler
hole, then reinstall the plug.
Gear Oil ReplacementTo change the gear oil in the manual trans-
mission, transfer case, extension case or
differential(s), use the following procedure:
1) Remove the oil filler plug (1).
2) Remove the drain plug (2), drain the oil
and reinstall the drain plug.
3) Pour new gear oil of the specified type
through the filler hole until the oil level
reaches the bottom of the filler hole.
4) Reinstall the filler plug.
(1)
(2)
(1)
(2)
WARNING
After driving the vehicle, gear oil tem-
perature may be high enough to burn
you. Wait until the oil filler plug is
cool enough to touch with your bare
hands before inspecting or replacing
gear oil.
CAUTION
When tightening these plugs, apply
sealing compound “SUZUKI Bond
No. 1217G” or equivalent to the plug
threads to prevent oil leakage and
tighten them to the specified torque
shown below.
Spark Plugs: 1, 2
Brakes: 6