Front Differential Transfer Drive Gear Assembly Installation

Special Tool 

J 45053 Universal Clamp Press 

Fig 1: Installing Front Differential Transfer Drive Gear Assembly

Courtesy of SUZUKI OF AMERICA CORP.

1. Inspect the front differential transfer drive gear assembly rear bearing assembly, located in the transmission case cover assembly, before installing the front differential transfer drive gear assembly (14) to be sure that all roller bearings are in the correct position.
   NOTE: When the front differential transfer drive gear assembly (14) is installed correctly, the front differential transfer drive gear assembly and the output gear will mesh evenly. If not, the front differential transfer drive gear assembly did not clear all 4-5 clutch plates in the 4-5 clutch assembly or is not seated into the front differential transfer drive gear assembly rear bearing assembly, located in the transmission case cover assembly.
2. Using J 45053 install the front differential transfer drive gear assembly (14) to the transmission case assembly.
   Fig 2: Installing Front Differential Transfer Drive Gear Thrust Bearing Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE: The front differential transfer drive gear thrust washer (264) is available as a select fit washer.
3. Using the front differential transfer drive gear thrust bearing washer (264) without any letter markings, install onto the front differential transfer drive gear assembly (14).
4. Install the front differential transfer drive gear thrust bearing assembly (263) onto the front differential transfer drive gear thrust bearing washer (264).
   Fig 3: Measuring Difference Between Straight Edge & Case

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5. Place a straight edge on the top of the rollers on the thrust bearing to reach across to the case surface.
6. Using a feeler gauge, measure (a) between the straight edge and the case.

   Specification 

   0.05-0.20 mm (0.002-0.008 in) 

7. If the measurement is not within specifications, refer to SHIM SIZE SPECIFICATIONS , Front Differential Transfer Drive Gear Thrust Bearing Washer (264), to select the correct thickness thrust washer.
   Fig 4: Identifying 1-2 Reverse Internal Gear

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8. If the measurement is not obtainable, using the thickest washer, the 1-2 reverse internal gear (594) will require removal and then a thicker shim (596) installed. Refer to 1-2-REVERSE CARRIER GEAR ASSEMBLY INSTALLATION .
9. Refer to SHIM SIZE SPECIFICATIONS , 1-2 Reverse Internal Gear Shim (596) to select the correct thickness of shim to obtain the correct measurement.
   Fig 5: Installing Front Differential Drive Gear

   Courtesy of SUZUKI OF AMERICA CORP.
10. Install again the front differential drive gear (14), the thrust washer and the thrust bearing.
    Fig 6: Measuring Thrust Bearing Height

    Courtesy of SUZUKI OF AMERICA CORP.
11. Measure the thrust bearing height (a) again to make sure it is in the specifications. If not within the specifications, adjust the height by changing the thrust washer.

    Reference: MANUAL SHIFT DETENT LEVER AND PARK PAWL INSTALLATION .