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HOMESERVICE MANUALSSUZUKI2013KIZASHI SPORT GTS, FWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 2 (TRANSFER ASSEMBLY)REPAIR INSTRUCTIONSTRANSFER ASSEMBLY DISASSEMBLY AND REASSEMBLYREASSEMBLY

2013 Suzuki Kizashi Sport GTS, FWD

Transfer Assembly Disassembly and Reassembly: Reassembly

2013 Suzuki Kizashi Sport GTS, FWDSECTION Reassembly

WARNING: This page is about a different variant/trim than selected.

Use special tool to install new oil seal (2) to transfer left case (1) directing oil seal lip as shown.
Special Tool

: 09913-85210
Use special tools to install new oil seal (3) to transfer left case directing oil seal lip as shown.
Special Tool
1. 09924-74510
2. 09944-88210
Fig 1: Installing Oil Seal To Transfer Left Case
Courtesy of SUZUKI OF AMERICA CORP.
Use special tool to install new oil seal (2) to transfer right case (1) directing oil seal lip as shown until depth reaches "a".
Oil seal (outer) installing depth

"a": 16 - 17 mm (0.6 - 0.7 in.)

Special Tool

: 09925-15410
Use special tool to install new oil seal (3) to transfer right case directing oil seal lip as shown until depth reaches "b".
Oil seal (inner) installing depth

"b": 3 - 4 mm (0.1 - 0.2 in.)

Special Tool
1. 09925-15410
Fig 2: Identifying Oil Seal Inner Depth
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to lip of all installed oil seals.
: Grease 99000-25011 (SUZUKI Super Grease A)
Install following parts to transfer right case (5).
- Oil pump inner rotor (1)
- Oil pump outer rotor (2)
- Oil pump outer cover (3)
- Oil pump drive pin (4)
Tighten new oil pump outer cover bolts (6) to specified torque.
CAUTION: The oil pump cover bolts are pre-coated with adhesive. If these bolts are reused, they may work loose. Be sure to replace the oil pump cover bolts with new ones whenever they are removed.

Tightening torque

Oil pump outer cover bolt (a): 8.0 N.m (0.82 kg-m, 6.0 lbf-ft)

Fig 3: Identifying Oil Pump Outer Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install new O-ring and oil strainer to transfer right case.
Use special tools and hydraulic press to install right bearing (1) to reduction driven gear (2).
Special Tool
1. 09924-74510
2. 09924-07730
Fig 4: Installing Right Bearing To Reduction Driven Gear
Courtesy of SUZUKI OF AMERICA CORP.
Use special tools and hydraulic press to install bevel gear (1) to reduction driven gear (2).
Special Tool
1. 09924-07710
2. 09924-84510-005
3. 09925-15410
Fig 5: Installing Bevel Gear To Reduction Driven Gear
Courtesy of SUZUKI OF AMERICA CORP.
Use special tools and hydraulic press to install left bearing (1) to reduction driven gear (2).
Special Tool
1. 09913-84510
2. 09924-84510-005
Fig 6: Installing Left Bearing To Reduction Driven Gear
Courtesy of SUZUKI OF AMERICA CORP.
Use special tool, bearing puller (3) and hydraulic press (4) to install bearings (1) to reduction drive gear (2).
Special Tool
1. 09913-85230
Fig 7: Installing Bearings To Reduction Drive Gear
Courtesy of SUZUKI OF AMERICA CORP.

Select reduction driven gear shim using the following procedures:

Calculate thickness of shim "e" with calculating formula.
"e" = ("b" + "c") - "a" + 0.1 mm (0.004 in.)
- "a": distance between outer race end of reduction driven gear bearings (mm (in.))
- "b": depth of bearing retaining surface on transfer left case (2) (mm (in.))
- "c": depth of bearing retaining surface on transfer right case (3) (mm (in.))
  
  Fig 8: Calculating Thickness Of Shim
  Courtesy of SUZUKI OF AMERICA CORP.

Select a shim which is close to half thickness of the calculated value (necessary shim thickness) from among the available shims to install it between bearing and case at each of right and left sides.

Available reduction driven gear left shim (2) thickness

REDUCTION DRIVEN GEAR LEFT SHIM THICKNESS SPECIFICATION

Select shim
1.00 mm (0.039 in.)
1.05 mm (0.041 in.)
1.10 mm (0.043 in.)
1.15 mm (0.045 in.)
1.20 mm (0.047 in.)
1.25 mm (0.049 in.)
1.30 mm (0.051 in.)
1.35 mm (0.053 in.)
1.40 mm (0.055 in.)

Available reduction driven gear right shim (4) thickness

REDUCTION DRIVEN GEAR RIGHT SHIM THICKNESS SPECIFICATION

Select shim
0.60 mm (0.024 in.)
0.65 mm (0.026 in.)
0.70 mm (0.028 in.)
0.75 mm (0.030 in.)
0.80 mm (0.031 in.)
0.85 mm (0.033 in.)
0.90 mm (0.035 in.)
0.95 mm (0.037 in.)
1.00 mm (0.039 in.)
1.05 mm (0.041 in.)

Fig 9: Identifying Reduction Driven Gear Left Shim

Courtesy of SUZUKI OF AMERICA CORP.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.