suzuki samuray User Manual

SECTION 14

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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

..........................................

.........................................

................................. 14-2

..................

...........................

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

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

Fig. 14-16

Remove bolts securing transfer front case,

and

take off case.

Speedometer Driven Gear

Loosen speedometer driven gear case bolt

and remove speedometer driven gear case with
gear.

Fig. 14-15

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. 14-17

By tapping output front shaft with a plastic
hammer,
front case.

Fig. 14-18

remove output front shaft from

14-8

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.

Fig. 14-21

Fig. 14-20

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

2) Using spring pin remover (special tool), drive
2 spring pins out of front drive shift shaft

@

and reduction shift shaft

Spring pin remover

@

0.

:

(09922-85811).

Fig. 14-26

Fig. 14-24

3) Remove forks and shift shafts.

NOTE:
At this time, locating ball and spring will jump
out of hole, use care not to lose them.

5) Pull out counter gear,
Remove counter shaft

loosening counter shaft

bearings and spacer.
from center case by
lock plate bolt.

Fig. 14-27

6) Remove input shaft from center case by
hammering thick part of case or input

shaft center with a plastic hammer.

Fig. 14-25

4) Hammer output rear shaft with a plastic

hammer to drive it out of center

case.

14-10

Fig. 14-28

7) Remove output shaft rear bearing and
retainer together by using bearing puller.
After removing bearing, speedometer drive
gear, thrust washer, output low gear and
needle roller bearing can be removed.

Fig. 14-29

8) Remove front drive clutch hub circlip and

pull clutch hub off shaft by using bearing
puller and puller attachment (special tool A).

(A)

09926-5801 0

Fig. 14-31

10) When input shaft is removed or center case
and rear case are separated, input shaft
bearings may come off. In such a case,
bearings can be removed from shaft by using
bearing puller.

NOTE:
Use care to prevent damage to needle roller
bearing in output rear shaft when removing

clutch hub.

/

(A)

099263801 0

Fig. 14-30

9) Remove front bearing by using bearing
puller and puller attachment (special tool

A).

NOTE:

Use care to prevent damage to needle roller
bearing in output rear shaft while bearing is
being removed.

**

i

ta

“+

Fig. 14-32

14-11

11) When input shaft is removed, front bearing
may be left in case. In this case, after remov­ing oil seal and circlip, bearing can be taken
out of case by using bearing installer (special
tool).

Bearing installer @ : (09913-75810)

Fig. 14-33

Transfer Rear Case

1) When center case and rear case are separated,
input shaft may be left in rear case. In this

case, remove input shaft from rear case by

hammering thick part of case with a plastic

hammer.

14-7. INSPECTION OF COMPONENTS

Gear Teeth

Inspect gear teeth 0, internal teeth of rear
clutch sleeve @ and clutch teeth of gear 3. for
wear, cracking, chipping and other
malcondition. Replace gear or sleeve as necessary.

Fig. 14-35

Fig. 14-34

14-12

Fig. 14-36

Locating Spring

Check each shifter fork shaft locating spring for

strength by measuring its free length. If length is

noted to be less than service limit, replace it.

Free length of
locating spring

Fig. 14-37

Bearings

Check each bearing by spinning its outer race by
hand to “feel” smoothness of rotation. Replace
bearing if noted to exhibit sticking, resistance
or abnormal noise when spun or rotated by

hand.

Fig. 14-38

Fig. 14-39 Output high gear

Fig. 14-40 Output low gear

Gear Shift Shafts

Check each part as indicated in below figures for
uneven wear. Replace defective parts.

Side Clearance of Gears

With gear, bearing and thrust washer installed
on shaft, check for side clearances of gears.

If clearance exceeds service limit, replace thrust

washer.

Side clearance

I

of gear

output

gears

low gear
high gear

Standard

0.175 ­(0.007 -

0.325mm

0.012in)

Service limit

0.7mm

(0.027in)

I

Fig. 14-41

14-13

4WD Gear Shift Lever
Check lower end of gear shift lever where gear
shift fork shaft contacts @ for wear and any

kind of damage. Worn or damaged shift lever

must be replaced with new one.

Fig. 14-42

14-8. REASSEMBLY

NOTE:

l All parts to be used in reassembly must be

perfectly clean.

l Oil or grease sliding and rubbing surfaces of

transfer components just before using them
in reassembly with gear oil and SUZUKI

SUPER GREASE A (99000-25010).

l

Oil seals, “0” rings, gaskets and similar sealing
members must be in perfect condition. For
these members, use replacement parts in
stock.

l Tightening torque is specified for important

-

fasteners

other components. Use torque wrenches and
constantly refer to specified data given in
P. 14-23.

Input Shaft
Press-fit bearings onto both sides of input shaft
by using bearing installer (special tool).
Bearing installer (A) :

mainly bolts - of transfer and

(09913-84510)

Fig. 14-43

(A)

14-14

Output Rear Shaft
Install following parts onto shaft in such order

and directions as prescribed in the figure.

6 9

1. Circlip

2. Hub

3.

Bearing

4.

Bearing

outer ring

5. Thrust washer

6. Output

7. Bearing (long)

8. Output rear shaft

high gear

9.

Sleeve

10. Bearing (short)

11. Outputlowgaar

12.

Thrust washer

13. Speed meter drive gear

14. Bearing

15. Retainer

2) Fit circlip @ securely into groove in shaft.

Fig. 14-46

3) After installing sleeve, bearing (short), low
gear and thrust washer, press-fit speedometer
drive gear by using bearing installer (special
tool).

Bearing installer (A) : (09913-84510)

(A)

Fig. 14-44

1) After installing bearing (long), high gear and
thrust washer, press-fit bearing 1. and then
hub @ by using bearing installer (special
tool).

Bearing installer (A) : (0991384510)

Fig. 14-45

Fig. 14-47

4) Press-fit bearing @ and the retainer @ by
using bearing installer (special tool).

Bearing installer (A) : (0991384510)

Fig. 14-48

14-15

Shim Adjustment of Input and Output Shafts

Clearance in thrust direction of both input and
output shafts is adjusted by putting shims
between input shaft rear bearing and rear case
for input shaft and between output shaft rear
bearing and rear case for output shaft.

As thrust clearance is specified as follows
determine shim thickness to meet specification
according to the following procedures.

Thrust clearance
specification

0.05 - 0.15 mm

(0.002 - 0.006 in.)

[Input shaft]

1) Take measurement “A” of rear case as shown
in figure below by using depth gauge,

2) Take measurement

“6”

of center case with

bearing circlip installed.

3) Take measurement

“C” (between bearing

inner races) of input shaft with bearings
installed, by using micrometer.

NOTE:

l

Before measuring, make sure that each

bearing

is free from abnormal noise or resistance by

spinning its outer race.

l Each measurement in above steps 1) to 3)

must be taken accurately in careful manner,

If shim thickness is determined based on
rough measurement, clearance of each shaft in
thrust direction will not satisfy specification.

And improper clearance may cause oil leakage,

broken bearing and abnormal noise.

l Take the same measurement at 3 to 4 diffe-

rent positions and use their mean.

1.1.

14-48-14-48-

Fig.Fig.

Fig. 14-48-1

Center caseCenter case

2.2.

Rear caseRear case

3.3.

Input shaftInput shaft

4. Output shaft4. Output shaft

11

Bearing circlipBearing circlip

5.5.
GasketGasket

6.6.
Gasket thicknessGasket thickness

7.7.

(0.3

mm or 0.012 in)

(0.3

mm or 0.012 in)

4) Using measurements obtained in steps 1) to 3)
and equation described below, calculate shim
thickness which is necessary for proper
thrust clearance.
Thrust clearance = (“A” + “B” + Gasket
thickness) - “C”
As the above equation holds for thrust
clearance and gasket thickness is specified as

0.3 mm and thrust clearance as 0.05 to 0.15
mm, shim thickness is calculated by the
following equation.

Shim thickness = (“A” + “B” + 0.3 )

-

(“C” + 0.05 - 0.15)

14-16

[Example]
Supposing A, B and C are as follows;
A = 81.35 mm (3.203 in.)

B = 35.70 mm (1.405 in.)
C = 117.05 mm (4.608 in.)
Shim thickness = (81.35 + 35.70 + 0.3)

6

(117.05 + 0.05 N 0.15)

=

117.35- 117.10~

-

117.20

= 0.25 - 0.15

In this case, use of 0.15 to 0.25 mm (0.006 to

0.009 in) thick shim(s) will ensure specified

thrust clearance which is 0.05 to 0.15 mm

(0.002 to 0.006 in). Therefore 2 pieces of

0.1 mm (0.004 in) thick shim should be
selected in available shims below to satisfy
thickness.

5) When shim thickness is determined, select
proper shim(s) from among the following
shims and use it (them) between input shaft
rear bearing and rear case when matching
center case and rear case.

Available shim 0.1,

size (thickness)

(0.004,0.012,0.020

0.3,0.5

mm

in.)

[Output shaft]

Just as with input shaft, take measurements of

“A’ “, “B’ ” and “C’ ” as indicated in Fig.
14-48-1, calculate shim thickness and install
proper shim(s) between output shaft rear bearing

and rear case when matching center case and

rear case.

I

Fig. 14-48-2

fig.

14-48-2

1. Shim for input shaft

2. Shim for output shaft

14-17

Rear Case

1) Install oil seal in rear case and apply grease
to oil seal lip.

Fig. 14-49

2) Install counter shaft thrust washer to rear
case, bringing its face without depressions
against case and fit its bent portion securely

into groove in case.

Center Case

1) Install input shaft front bearing circlip and
oil seal in center case.
Snap ring pliers @ : (09900~6108)

Fig. 14-51

2) Install input shaft to center case.

NOTE:
Apply ample amount of grease to both surfaces
of washer so as to lubricate sliding surfaces and
prevent washer from moving out of place or

slipping off.

Fig.

14-50

Fig. 14-50

Fig. 14-52

Fig.

14-52

3) After greasing 0 ring on counter shaft,
insert shaft into center case and secure
shaft with lock plate and bolt.

14-18

Fig. 14-53

Fig.

14-53

4) Install the counter shaft thrust washer to
center case. For installation, apply ample
amount of grease to both faces of the washer
so as to lubricate sliding surfaces and prevent

it from moving out of place or slipping off

and bring its face without depressions against

center case, and fit its bent portion into
groove in case securely.

Fig. 14-54

Fig.

14-54

Fig. 14-56

Fig. 14-56

7) When installing front drive shift shaft and
reduction shift shaft in center case, install
spring 0, ball 0, shaft 0, ball @, shaft

0,

ball 8, spring 0 and plug 8. in that

order.

5) Install needle roller bearings, spacer and
counter gear on counter shaft.

Fig. 14-55

Fig. 14-55

6) Install output shaft assembly to center case.

d 18-3ON.m

Fig. 14-57

Fig. 14-57

8) Fit forks on shift shafts and lock them
with spring pins. Forks should be fitted in
correct direction

according to below figure.

(1.8 - 3.0 kg-m
(13.5 - 21.5

lb-ft)

1

Fig. 14-58

Fig. 14-58

14-19

14-19

Center and Rear Cases

1) Check center case (or rear case) to ensure
that it is provided with 2 dowel pins

0.

Fig. 14-59

2) Put gasket on center case. Bring rear case
and center case into match and apply
uniform force gradually all around rear case
with a plastic hammer. Tighten center case
securing bolts to specified torque.

Fig. 14-61

NOTE:

l

Matching must be made carefully so as not to

move countershaft thrust washers out of place.

l

Be sure to install shims determined in previ-

ous item
Output Shafts”

“Shim Adjustment of Input and

between input shaft rear

bearing and rear case and between output

shaft rear bearing and rear case.

Fig. 14-60

Fig. 14-62

3) Apply grease to output front shaft rear
bearing.

Fig. 14-63

14-20

Front Case

1) Install bearing, circlip and oil seal to front
case. Apply grease to oil seal lip and install
output front shaft using bearing installer

(special tool).
Bearing installer (A) : (09913-76010)

Fig. 14-64

2) Put gasket on center case.

3) Check front case to ensure that it is provided
with 2 dowel pins.

Fig. 14-66

5) When installing speedometer driven gear
and its gear case in rear case, apply grease to
0 ring and oil seal lip, and align bolt holes
in rear case and driven gear case.

Fig. 14-65

4) Install front case to center case.

Fig. 14-67

6) Install 4WD ball and switch. Then clamp
switch lead wire properly.

/

Fig. 14-68

1.6 - 2.3 kgm
(12.0 - 16.5

lb-h)

14-21

7) Install propeller shaft flanges and tighten
nuts to specified torque and

talk

the nuts.

8) Upon completion of entire assembly work,

install transfer in chassis body in reverse
sequence of removal. Pour gear oil into
transfer gear box.

Refer to information given in next oil and

oil capacity for oil to be used and specified

amount.

NOTE:

When installing oil filler and drain plugs to

transfer case, apply sealant (SUZUKI BOND

No.1215, 99000-31110) to thread part of plug.

14-9. MAINTENANCE SERVICES

Oil Level

Oil level must be checked with car held in
horizontal position in both front to rear and side
to side directions.
Oil level plug and oil filler plug are one and the

same as shown in figure.

If oil flows out of filler plug hole or if oil level is
found up to hole when plug is removed, amount
of oil is appropriate. Replenish oil if noted as

insufficient.

Oil and Oil Capacity

Whenever car is lifted up for any service includ­ing oil change,
transfer gear box for oil leakage. Correct defects,
if any, and change or refill oil.

make sure to check around

Transfer oil capacity

Transfer oil Gear oil SAE
specification

0.8 litre

75W-80

(1.7/l .4

8OW-90,

or

75W-90

US/Imp. pt)

It is highly recommended to use SAE
gear oil.
For viscosity chart, refer to P. 1-20.

@ : Oil drain plug

Fig. 14-70

@ : Oil filler & level plug

75W-90

14-22

14-10. TIGHTENING TORQUE

Fastening parts

Front case bolt

Center case bolt

Counter shaft lock

Counter shaft lock

plate bolt

Universal

Universal joint

joint flange

flange nut

Transfer mounting
bracket bolt

Transfer mounting nut

Cross joint bolt & nut

Oil filler and drain
plug

14-23