2006 SUZUKI SX4 Oil ring

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 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-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 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

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 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)