2006 SUZUKI SX4 Transfer case

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 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-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 Transfer: 3C-14
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

Downloaded from www.Manualslib.com manuals search engine 3C-15 Transfer:
4) Bring painted part up and check contact pattern referring to the following chart. If contact pattern is not normal,
readjust or replace as necessary according to instruction in chart.
NOTE
• Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.
• If bevel gear back lash and bevel pinion shims are adjusted properly, correct tooth contact should
be provided.
If correct tooth contact is not provided even when they are adjusted properly, however, there may be
an abnormal condition in worn tooth, transfer case or retainer. Check each component and replace
as necessary.

Gear tooth contact table
Tooth contact pattern Diagnosis and remedy
Normal
High contact
Pinion is positioned too far from the center of drive bevel
gear.
• Decrease thickness of bevel pinion shim and position
pinion closer to gear center.
• Adjust drive bevel gear backlash to specification.
Low contact
Pinion is positioned too close to the center of drive bevel
gear.
• Increase thickness of bevel pinion shim and position
pinion farther from gear center.
• Adjust drive bevel gear backlash to specification.
These contact patterns indicate that the “offset” of
reduction driven gear is too much or too little. The
remedy is to change the division of the bevel gear
shim(s).
I5RW0A330045-01
I3RH01332045-01
I3RH01332046-01
I3RH01332047-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-16
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)

Downloaded from www.Manualslib.com manuals search engine 3C-17 Transfer:
Special Tools and Equipment
Recommended Service MaterialS6RW0D3308001
NOTE
Required service material is also described in the following.
“Transfer Assembly Components”

Special ToolS6RW0D3308002
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) / ) / ) / )
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09912–34510 09913–50121
Case separator Oil seal remover
)) / )
09913–75520 09913–76010
Bearing installer Bearing installer
))
09913–84510 09913–85210
Bearing installer Bearing installer
) / ) / ))
09913–85230 09922–76140
Bearing remover tool Bevel pinion shaft
) / )) / )
09922–76150 09922–76340
Bevel pinion nut Bevel pinion rear collar
))

Downloaded from www.Manualslib.com manuals search engine 5A-164 Automatic Transmission/Transaxle:
09926–97620 09926–98310
Spring compressor Clutch spring compressor
) / )) / )
09928–06050 09942–15511
Differential preload adapter Sliding hammer
) / )) / ) / ) / )
09944–78210 09944–88220
Bearing installer support Oil seal installer
) / )) / ) / ) / )
09944–96011 09946–06710
Bearing outer race remover Transfer bearing dummy
) / ) / ) / )) / )
09951–18210 09952–06020
Oil seal remover & installer
No. 2Dial gauge plate No.2
) / )) / ) / ) / )
SUZUKI scan tool (SUZUKI-
SDT)
—
This kit includes following
items. 1. SUZUKI-SDT 2.
DLC3 cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case ) / )
1
2
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