Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 46

3C-79 Transfer: Non-Shift Type (Transfer without Shift Actuator)

2) Install input gear assembly (1) to front case (2).

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)

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.

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

6) Install rear output shaft assembly (2) to rear case (3), 

and then install snap ring (1).

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

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

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

sprocket (2).

1

2

I5JB0A331092-01

1, (a)

I5JB0A331093-03

(A)

1

2

“a”

I5JB0A331036-02

(A)

1, “A”

2

“a”

I5JB0A331094-04

1

2

3

I5JB0A331025-01

1

2

3

5

4

I5JB0A331024-01

1

2

I5JB0A331039-01

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-80

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 (2) 

and needle bearings (1) to rear output shaft (3).

11) Install center differential assembly (1) to rear output 

shaft (2).

12) Install reduction shift sleeve (1) to rear output shaft 

(2).

13) 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 
becomes specified value.

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

Available shim thickness

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

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

15) Install needle bearing (1) to center 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

[A]: Rear case side

1

2

I5JB0A331040-01

1

1

2

3

4

I5JB0A331041-02

1

2

[A]

I5JB0A331095-02

1

2

I5JB0A331096-01

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

3

4

2

I5JB0A331097-01

1

2

3

I5JB0A331098-02

1

(A)

2

“a”

I5JB0A331099-02

3C-81 Transfer: Non-Shift Type (Transfer without Shift Actuator)

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

(3).

17) Install 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

18) Clean mating surface of both center case and rear 

case (1), apply sealant to rear case as shown in 
figure by such amount that its section is 1.2 mm 
(0.047 in.) in diameter, mate center case with rear 
case and then tighten bolts (2) to specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Rear case bolt (a):  23 N·m (2.3 kgf-m, 17.0 lb-ft)

19) Clean mating surface of both center case (1) and 

front case, apply sealant to center case as shown in 
figure by such amount that its section is 1.2 mm 
(0.047 in.) in diameter, mate front case (3) with 
center case and then tighten bolts (2) to specified 
torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Rear case bolt (a):  23 N·m (2.3 kgf-m, 17.0 lb-ft)

20) Install oil strainer (1) to rear case (2).

Tightening torque
Strainer bolt (a):  10 N·m (1.0 kgf-m, 7.5 lb-ft)

21) Install oil pump inner rotor (3), outer rotor (4) and 

drive pin (5) to rear case.

2

1

3

(A)

4, “A”

“a”

I5JB0A331100-03

“A”

1

1

2, (a)

I5JB0A331101-02

“A”

1

2, (a)

2, (a)

3

I5JB0A331102-02

2

5

1

(a)

4

3

I5JB0A331103-01

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-82

22) Clean mating surface of oil pump cover (1) and rear 

case (2), apply sealant to rear case as shown in 
figure by such amount that its section is 1.2 mm 
(0.047 in.) in diameter, mate oil pump cover with rear 
case and then tighten bolts (3) to specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Oil pump cover bolt (a):  23 N·m (2.3 kgf-m, 17.0 
lb-ft)

23) Clean mating surface of differential lock shift lever 

case (1) and center case (5), apply sealant to center 
case as shown in figure by such amount that its 
section is 1.2 mm (0.047 in.) in diameter, confirm the 
each fork of lever case is in groove of the sleeve, 
mate differential lock shift lever case with center 
case and then tighten differential lock shift lever case 
bolts (3) to which thread lock cement has been 
applied and differential lock shift lever case dowel 
bolts (4) to specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)
“B”:  Thread lock cement 99000–32110 (Thread 
Lock Cement Super 1322)

Tightening torque
Differential lock shift lever case bolt (a):  23 N·m 
(2.3 kgf-m, 17.0 lb-ft)
Differential lock shift lever case dowel bolt (b):  
23 N·m (2.3 kgf-m, 17.0 lb-ft)

Input Gear Assembly Disassembly and 
Reassembly

S5JB0E3326007

Refer to “Input Gear Assembly Disassembly and 
Reassembly: Motor-Shift Type (Transfer with Shift 
Actuator)”.

Front Output Shaft Assembly Disassembly and 
Reassembly

S5JB0E3326008

Refer to “Front Output Shaft Assembly Disassembly and 
Reassembly: Motor-Shift Type (Transfer with Shift 
Actuator)”.

Rear Output Shaft Assembly Disassembly and 
Reassembly

S5JB0E3326009

Refer to “Rear Output Shaft Assembly Disassembly and 
Reassembly: Motor-Shift Type (Transfer with Shift 
Actuator)”.

“A”

3, (a)

3, (a)

1

2

I5JB0A331104-01

“A”

2

1

3, “B”, (a)

3, “B”, (a)

4, (b)

I5JB0A331105-03