Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Transfer Case Assembly

Print

REMOVAL & INSTALLATION



Samurai Models

Even the 2WD Samurai uses a transfer case. Rather than use a straight line driveshaft from the transmission to the differential, the Samurai leaves the transfer case in place and replaces its internal working with a simple offset gear mechanism, thus keeping 2 of the 3 driveshafts used in the 4WD vehicle.

  1. On 4WD vehicles, remove the transfer case shift lever.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Drain the oil from the transfer case.
  6.  
  7. Matchmark and remove the driveshafts from the transfer case assembly. Not all of the driveshafts need to be completely removed from the vehicle, just unbolted from the case flanges. In most cases, the shaft or shafts on one side of the transfer case can be repositioned and supported out of the way.
  8.  
  9. Support the transfer case using a suitable transmission jack.
  10.  
  11. Disconnect the speedometer cable from the transfer case.
  12.  
  13. On 4WD vehicles, disconnect the 4WD switch lead wire at the coupler.
  14.  
  15. Remove the three mounting bolts and/or nuts securing the transfer case to the chassis, as applicable.
  16.  
  17. Carefully lower the transfer case from the vehicle.
  18.  

To install:
  1. Position and install the transfer case. Tighten the mounting bolts to 159-248 inch lbs. (18-28 Nm) and/or the mounting nuts to 19-25 ft. lbs. (25-34 Nm).
  2.  
  3. On 4WD vehicles, connect the 4WD switch lead wire at the coupler.
  4.  
  5. Connect the speedometer cable to the transfer case.
  6.  
  7. Properly refill the transfer case with an approved type of gear oil.
  8.  
  9. Align and install the driveshafts to the transfer case.
  10.  
  11. On 4WD vehicles, install the transfer case shift lever.
  12.  
  13. Remove the jackstands and carefully lower the vehicle.
  14.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

On these models the transfer case is bolted to the transmission and takes the place of the 2WD transmission's extension housing. Therefore, transfer case is removed or installed as part of the transmission assembly.

 
label.common.footer.alt.autozoneLogo