Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 263

3C-83 Transfer: Non-Shift Type (Transfer without Shift Actuator)

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

output shaft (2).

13) 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.

14) Remove snap ring (1), and then rear output shaft 

assembly (2) from rear case (3).

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

end rod or the like, if necessary.

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

special tool, if necessary.

Special tool
(A):  09913–76010

17) Remove input gear plate (1), and then remove input 

gear assembly (3) from front case (2).

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

using flat end rod or the like, if necessary.

Reassembly

1) Install 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

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I5JB0A331023-01

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I5JB0A331024-01

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I5JB0A331025-01

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(A)

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I5JB0A331091-01

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I5JB0A331030-01

(A)

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I5JB0A331033-01

Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-84

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.

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2

I5JB0A331092-01

1, (a)

I5JB0A331093-03

(A)

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“a”

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(A)

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“a”

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3C-85 Transfer: Non-Shift Type (Transfer without Shift Actuator)

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 (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).

[A]: Rear case side

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[A]

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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.)

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Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-86

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

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)

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(A)

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“a”

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(A)

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“a”

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“A”

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