Suzuki Aerio, Verona 2002-06

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Mark the driveshaft CV joint in relation to the transfer case assembly flange.



    Front right wheel and tire
     
    Front right halfshaft
     
    Engine splash guard
     
    The mounting for the center bearing for the driveshaft
     



    Bolts on driveshaft using counterhold 999 7057
     
    Press the driveshaft CV joints together and remove driveshaft
     
    Remove bolts holding the transfer case and pull it straight out from the transaxle assembly
     

  4.  

To install:


NOTE
Before installing the transfer case, lubricate the spline joint that joins to the transaxle. Make sure that the mating surfaces on the transaxle and transfer case are clean and not damaged.

  1. Use new bolts to attach transfer case. Tighten the bolts alternately to light contact. Then, tighten alternately to 37 ft. lbs. (50 Nm).
    NOTE
    Check carefully that the mating surfaces on the driveshaft CV joint and flange are clean.

  2.  
  3. Install or connect the following:

    The driveshaft according to the previous marking. Use new bolts and counterhold 999 7057 to tighten driveshaft bolts to 18 ft. lbs. (24 Nm).
     
    The center bearing and member for the driveshaft. Use new bolts and tighten to 18 ft. lbs. (24 Nm).
     
    Right front halfshaft to the wheel hub. Refer to Halfshafts removal and installation
     

  4.  
  5. Fill the transaxle with proper amount of oil.
  6.  
  7. Check the oil level in the transfer case. Fill with oil up to the filling plug.
  8.  
  9. Install engine splash guard.
  10.  
  11. Install right front wheel and tire. Tighten lug nuts to 102 ft. lbs. (138 Nm).
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Transfer breather hose from clamp on intake manifold
     
    Exhaust cover and exhaust No. 1 pipe nuts
     
    Heated oxygen sensor
     

  6.  
  7. Support engine using engine hanger.

    Front wheels
     
    Transaxle fluid and transfer case fluid
     
    Ball joints from steering knuckles
     
    Stabilizer joint
     
    Engine rear mounting nuts
     
    Exhaust No. 2 pipe hanger bush from suspension frame
     
    Engine front mounting nuts and mounting member to body bolts
     

  8.  
  9. Support the suspension frame using a transmission jack.
  10.  
  11. Remove 6 suspension frame bolts and lower the suspension frame with suspension arms and stabilizer.

    Front of propeller shaft from transfer output flange
     
    Exhaust No. 1 pipe stay
     
    Exhaust No. 1 pipe
     
    Exhaust No. 2 pipe
     
    Right side drive shaft
     
    Transfer case to transaxle stiffener
     
    Transfer case to engine stiffener
     

  12.  
  13. Support the transfer case assembly using a transmission jack.

    Transfer case mounting bolts
     
    Transfer case from transaxle
     

  14.  

To install:

  1. Remount the transfer case assembly by reversing the removal procedure.
  2.  
  3. Tighten the bolts and nuts to the specified torque as follows.

    Engine rear mounting bracket nut: 14.5 ft. lbs. (20 Nm)
     
    Transfer case mounting bolts: 36.5 ft. lbs. (50 Nm)
     
    Transfer case to engine stiffener bolts: 36.5 ft. lbs. (50 Nm)
     
    Transfer case to transaxle stiffener bolts: 36.5 ft. lbs. (50 Nm)
     
    Propeller shaft No. 1 bolts: 17 ft. lbs. (23 Nm)
     
    Exhaust No. 2 pipe to muffler bolts: 31.5 ft. lbs. (43 Nm)
     
    Suspension frame bolts: 65 ft. lbs. (90 Nm)
     
    Engine rear mounting nuts: 40 ft. lbs. (55 Nm)
     
    Ball joint lock nuts: 43.5 ft. lbs. (60 Nm)
     
    Exhaust No. 2 pipe to No. 1 pipe bolts: 31.5 ft. lbs. (43 Nm)
     
    Exhaust No. 1 pipe stay bolts: 36.5 ft. lbs. (50 Nm)
     
    Engine front mounting nuts: 32.5 ft. lbs. (45 Nm)
     
    Mounting member to body bolts: 39.5 ft. lbs. (55 Nm)
     
    Wheel lug nuts: 61.5 ft. lbs. (85 Nm)
     
    Remaining components in the reverse order of removal
     

  4.  
  5. Fill the transaxle and the transfer case with the correct type and amount of fluid.
  6.  
  7. Connect the negative battery cable.
  8.  

 
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