Suzuki Grand Vitara 1998, Service Manual

Page: 497 / 801

YH4
GRAND
VITARA
7D-2 TRANSFER
DIAGNOSIS
DIAGNOSIS TABLE
Before attempting to repair the transfer or related components for any reason other than mechanical failure, the
condition and probable causes should be identified.
Transfer failures are revealed by shifting difficulties such as excessive shifting effort, gear clash, or gear grinding.
When any of these conditions occur, the following inspections should be made before disassembling the transfer.
1) Check transfer oil level for insufficient or incorrect oil. Refer to “Transfer and Differential Oil Inspection and
Change” in SECTION 0B “MAINTENANCE AND LUBRICATION”.
2) Check transfer mountings for wear or looseness.
3) Check gearshift control lever for distortion or excessive wear.
After performing the above inspections, refer to following diagnosis table.
Condition Possible Cause Correction
Gear slipping out of mesh Worn shift fork shaft
Worn shift fork or synchronizer sleeve
Weak or damaged locating spring
Worn bearings on output rear shaft
Worn chamfered tooth on sleeve or gear
Missing or disengagement of circlip(s)
Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengage Weakened or broken synchronizer spring
Distorted shift shaft or shift fork
Replace
Replace
Hard shifting Weakened front drive shift shaft spring
Distorted or mispositioned front drive shift
shaft circlip and washer
Inadequate or insufficient lubricant
Worn synchronizer ring
Worn chamfered tooth on sleeve or gear
Distorted shift shaft
Replace
Replace
Replenish
Replace
Replace sleeve and gear
Replace
Noise Inadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer ring
Damaged or worn chamfered tooth on
sleeve or gear
Replenish
Replace
Replace
Replace
Replace