suzuki samuray User Manual
SECTION 14
www.zukioffroad.com
TRANSFER GEAR BOX
CONTENTS
14-l.
14-2.
14-3.
14-4.
14-5.
14-6.
14-7.
14-8.
14-9.
14-10.
GENERAL DESCRIPTION
SELECTIVE FLOWS OF TRANSFER DRIVE
GEAR RATIO DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
TRANSFER SERVICES NOT REQUIRING
TRANSFER REMOVAL . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . 14-5
REMOVAL .............................................
DISASSEMBLY
INSPECTION OF COMPONENTS
REASSEMBLY
MAINTENANCE SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22 12
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23
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................................. 14-2
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14-3
14-6
14-8
14-12
14-14
14-1
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
Oil seal
2.
3. Circlip
Bearing
4.
5. Nut
Input shaft
6.
7. Bearing
Counter shaft lock plate
8.
9. O-ring
Counter shaft
10.
Bearing
11.
12.
Spacer
Thrust washer
13.
14. Counter gear
Flange
15.
16.
Oil seal
17. Circlip
18.
Bearing
Output front shaft
19.
Bearing
20.
21. Circlip
Sleeve
22.
Hub
23.
24.
Bearing
Thrust washer
25.
Bearing
26.
Output high gear
27.
Sleeve
28.
Output rear shaft
29.
Output low gear
30.
31.
Bearing
Speedometer drive gear
32.
Bearing
33.
Retainer
34.
Oil seal
35.
Speedometer driven gear
36.
Speedometer gear case
37.
Oil seal
38.
Shim
39.
Flange
40.
Washer
41.
Fig.
14- 1
Fig. 14-1
14-2
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 shaft
through big gear, “high” gear and rear clutch.
Gear shift control lever position
a-wheel drive
(Rear wheel drive)
tra”SmiSSion
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
ring, thus coupling output rear shaft to output
front shaft. Front shaft and rear
together on HIGH.
Gear shift control lever position
4-wheel
drive HIGH
shaft run
To front wheel
From
.
transm’ss’on
e
Fig. 14-3
14-3
4-Wheel Drive LOW (All-Wheel Drive on LOW)
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
LOW.
Gear shift control lever position
4-wheel
drive LOW
2H
From
5l
Fig. 14-4
14-3. GEAR RATIO DATA
Gear
To front whe
Rear-wheel drive
41/44 -
62/41
All-wheel drive high
41/44
-
62/41
All-wheel drive low
41/44 - 56/23
14-4
Reduction
1.409
1.409
2.268
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 Component
1. Universal-joint yoke flanges
2. Front drive shift shaft fork
3. Transfer output front shaft oil seal
4. Transfer output front shaft bearing
5. Transfer output front shaft
6. Transfer front case
7. Front drive clutch hub
8. Front drive clutch sleeve
9. Transfer input shaft oil seal
10. 4WD indicator light switch
11. Speedometer driven gear
12. Gear shift control lever
13. Gear shift control boot No. 1, No. 2
14. Gear shift control lever spring seat
.
Nature of Service
Replacement or inspection
Replacement or inspection
I
Replacement or inspection
Replacement
Replacement
Replacement
Replacement or inspection
Replacement or inspection
Replacement
Replacement or inspection
Replacement or inspection
Replacement or inspection
Replacement
Replacement 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 drain
plug.
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.
14-8
5) Disconnect speedometer drive cable from
transfer gear box.
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.
Fig. 14-11
14-7
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