Intermediate Shaft Disassembly and Reassembly

Intermediate Shaft Disassembly and Reassembly

Transfer Dismounting and Remounting

Transfer Assembly Components

Disassembly

1) Remove oil seal (1) and snap ring (2) from transfer right case (3).





2) Tap intermediate shaft (1) from transfer left case (2) side with plastic hammer (3) and remove it together with bearing.











3) Remove circlip (1) from intermediate shaft (2).
4) Remove intermediate shaft bearing (5) from intermediate shaft by using bearing puller (3) and hydraulic press (4).






Reassembly

1) Install intermediate shaft bearing (3) to intermediate shaft (4) by using special tool, bearing puller (1) and hydraulic press (2).
Special Tool

(A): 09913-85210





2) Install new circlip (1) to intermediate shaft (2).
3) Install intermediate shaft to transfer from transfer right case (3) side.











4) Install new snap ring (1) to transfer right case (2).





5) Apply grease to new oil seal (1) lip.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)

6) Use special tool and hammer to install oil seal in transfer right case (2).

Intermediate output oil seal installing depth
"a": 2.0 - 3.0 mm (0.1 - 0.2 in.)

Special Tool

(A): 09925-16010