Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 41

3C-59 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

13) Remove differential lock clutch sleeve (1) from rear 

output shaft (2).

14) Remove front drive sprocket bush (1) from rear 

output shaft (2).

15) Take out front drive sprocket (1), front output shaft 

assembly (2), drive chain (3) and needle bearing (4) 
from rear case (5) all at once.

16) Remove snap ring (1), and then remove rear output 

shaft assembly (2) from rear case (3).

17) Remove rear oil seal (1) from rear case (2) using flat 

end rod or the like, if necessary.

18) Remove needle bearing (1) from rear case (2) using 

special tool, if necessary.

Special tool
(A):  09913–76010

19) Remove input gear plate bolts (1) from front case (2).

1

2

I5JB0A331022-01

1

2

I5JB0A331023-01

1

2

3

5

4

I5JB0A331024-01

1

2

3

I5JB0A331025-01

1

2

I5JB0A331026-01

(A)

1

2

I5JB0A331027-01

1

2

I5JB0A331028-02

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-60

20) Remove input gear assembly (1) and counter gear 

assembly (2) from front case (3) using plastic 
hammer.

21) Remove front oil seal No.2 (1) from front case (2) 

using flat end rod or the like, if necessary.

Reassembly

1) Install new front oil seal No.2 to front case (1) using 

special tool, and then apply grease to oil seal lip.

:  Grease 99000–25010 (SUZUKI Super Grease A)

Special tool
(A):  09913–85210

2) Install counter gear assembly (1) to front case (2), 

and then install input gear assembly (3).

NOTE
Install input gear plate (4) so as not to hit 
counter gear assembly.

 

3) Tighten new input gear plate bolts (1) to specified 

torque.

Tightening torque
Input gear plate bolt (a):  23 N·m (2.3 kgf-m, 17.0 
lb-ft)

3

1

3

1

2

I5JB0A331029-01

1

2

I5JB0A331030-01

(A)

1

I5JB0A331033-01

2

3

1

1

2

4

3

I5JB0A331034-02

1, (a)

I5JB0A331035-03

3C-61 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

4) Install needle bearing (1) to rear case (2) using 

special tool as shown in figure.

Distance between case and needle bearing “a”
: 0 – 0.5 mm (0 – 0.008 in.)

Special tool
(A):  09913–76010

5) Install new rear oil seal (1) to rear case (2) using 

special tool as shown in figure, and then apply 
grease to oil seal lip.

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A)

Distance between case and oil seal “a”
: 3.5 – 4.5 mm (0.138 – 0.177 in.)

Special tool
(A):  09913–70123

6) Install rear output shaft assembly (1) to rear case (2), 

and then install snap ring (3).

7) Install front drive sprocket (1), front output shaft 

assembly (2), drive chain (3) and needle bearing (4) 
into rear case (5).

8) Install front drive sprocket bush (1) into front drive 

sprocket (2).

9) Install differential lock clutch sleeve (1) to rear output 

shaft (2) as shown in figure.

10) Install thrust needle bearing (4), front drive shaft (1) 

and needle bearings (2) to rear output shaft (3).

(A)

1

2

“a”

I5JB0A331036-02

“a”

(A)

1, “A”

2

1

2

I5JB0A331037-04

1

2

3

I5JB0A331038-01

1

2

3

5

4

I5JB0A331024-01

1

2

I5JB0A331039-01

1

2

I5JB0A331040-01

1

1

2

3

4

I5JB0A331041-02

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-62

11) Install low gear (3), center differential (4) and 

reduction shift sleeve (1) to rear output shaft (2).

12) Select shim (1) as follows.

a) Install shim, washer (2) and used snap ring (3) 

into rear output shaft (4).

b) Check clearance between shim and washer.
c) If clearance is out of specified value, select shim 

from the following table so that clearance 
become specified value.

Clearance between shim and washer
: 0.1 – 0.3 mm (0.004 – 0.012 in.)

Available shim thickness

13) Remove used snap ring, and then install new snap 

ring (2) and needle bearing (1) to rear output shaft 
(3).

14) Install needle bearings (1) to center case (2) using 

special tools as shown in figure.

Distance between case and needle bearing “a”
: 0 – 0.5 mm (0 – 0.008 in.)

Special tool
(A):  09913–76010
(B):  09925–98210

15) Install oil pipe (1) and knock pin (2) into center case 

(3).

16) Install new front oil seal No.1 (4) into center case 

using special tool as shown in figure, and then apply 
grease to oil seal lip.

Distance between case and oil seal “a”
: 3.5 – 4.5 mm (0.138 – 0.177 in.)

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A)

Special tool
(A):  09913–70123

[A]: Rear case side

0.4 mm (0.016 in.)

1.6 mm (0.063 in.)

0.6 mm (0.024 in.)

1.8 mm (0.071 in.)

0.8 mm (0.031 in.)

2.0 mm (0.079 in.)

1.0 mm (0.039 in.)

2.2 mm (0.087 in.)

1.2 mm (0.047 in.)

2.4 mm (0.098 in.)

1.4 mm (0.055 in.)

1

2

4

[A]

4

3

I5JB0A331042-02

1

3

2

4

I5JB0A331043-01

1

2

3

I5JB0A331044-02

1

2

(B)

(A)

“a”

I5JB0A331045-02

2

1

3

(A)

4, “A”

“a”

I5JB0A331046-03