Transfer Case

Driveshaft/axle - Transfer
Course code: DS02

Student training manual

Suzuki Online Training
 Foreword Suzuki Technician curriculum

A 4 Wheel Drive systems distributes driving force generated by
the engine to both the front and the rear wheels to improve
traction. A transfer is a supplementary gear change system for
switching between 2 wheel drive, 4 wheel drive and 4 wheel
drive low. In this training manual, we will study the transfer
system used in the 4WD system. The Suzuki Jimny SN413 is
used for description of the transfer system.
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This training manual is part of the Non Suzuki Technician to
Suzuki Technician curriculum. The curriculum consists of the
following modules:
1. GE01 Suzuki Introduction
2. GE02 Electrical / Electronics
3. GE03 Diagnostics
4. EN02 Engine Mechanical part I
5. EN03 Engine Mechanical part II
6. EN04 Engine Mechanical part III
7. EN05 Engine Auxiliary systems
8. DS01 Driveshaft/Axle
9. DS02 Driveshaft/Axle transfer case
10. BR02 Brake control systems
11. Manual transmission / transaxle
12. CS02 Control system / body electrical
13. CS03 Communication / bus systems
You are currently studying DS02 Driveshaft/Axle Transfer case.
This module consists of the following courses:

• Transfer case
This document is intended solely for training purposes only.
• DS02 practical activities
All vehicle repairs and adjustments must be carried out
according to the procedures stipulated in current service
manuals and technical bulletins.

DS02 Driveshaft/Axle Transfer box 2

 Table of contents

Topic Page

4WD system 4
Transfer 5
Transfer control system 6
Transfer components 7
Power transmission in the transfer 8
Transfer controller/4WD control module 11
2H to 4H shift control 12
4H to 2H shift control 13
4H to 2L shift control 13
4H to 4L shift control 14
4WD indicator control 15
Description of limited shift operation 17
Basic tests of 4WD components 18
4WD on-board diagnostic system 20
DTC check 21
Fail safe table 23
Service information 24

DS02 Driveshaft/Axle Transfer box 3

 4 Wheel Drive system Function of 4WD system components

(1) 4WD switch: Detects whether transfer shift fork shaft No.1
is at 2H or 4H/4L.

(2) 4WD low switch: Detects whether transfer shift fork shaft
No.1 is at 2H/4H or 4L

(3) 2WD/4WD switch

(figure 3 A)

• 2WD switch (16): Shifts transfer from 4H to 2H or from 4L

to 2H.
• 4WD switch (17): Shifts transfer from 2H to 4H or from 4L
to 4H.
• 4WD-L switch (18): Shifts transfer from 4H to 4L or from 2H
to 4L.

(4) 4WD indicator

(figure 3B)

• Indicates whether transfer is at 4H/4L position or not.

Figure 1: Location of 4WD components (Jimny SN413) • Informs what state transfer control system is.

[1] 4WD low indicator [2] 4WD indicator

(5) 4WD-L indicator (B-20)
[3] 2WD/4WD switch [4] 2WD switch
[5] 4WD switch [6] 4WD-L switch • Indicates whether transfer is at 4L position or not.
[7] 4WD switch connector [8] 4WD low switch connector • Informs what state transfer control system is.
[9] Transfer shift actuator connector
[10] Transfer shift actuator motor
[11] VSS [12] 4WD control module

DS02 Driveshaft/Axle Transfer box 4

 (6) Clutch pedal switch Transfer
Detects whether clutch pedal is depressed or not.

(7) Warning buzzer

Warns what state transfer control system is. 4

(8) 4WD control module 3

• Controls transfer shifting. 1
• Controls air locking hub operating
• Operates 4WD indicator, 4WD low indicator and warning
buzzer.
2
• Diagnoses 4WD control system components.
Figure 2: Drivetrain layout
(9) Transfer shift actuator
Consists of transfer shift actuator motor and transfer shift [1] Transfer [2] Front differential
actuator limit switch. [3] Rear differential [4] Transmission

(10) Transfer shift actuator motor
Shifts transfer shift position by operating shift fork shaft No.1
through pinion gear.
(11) Transfer shift actuator limit switch
Detects whether transfer shift actuator motor position.
The aluminum transfer case directly connected to the back of
the transmission contains input shaft, counter gear, output
rear shaft, output front shaft, drive chain, shift fork shaft No.1,
shift fork shaft No.2 and their accompanying gears, hubs,
sleeves, synchronizer ring, fork, etc.
With a synchronizer installed to the front drive clutch hub
sleeve, it is possible to change the shift position between the
2H position and the 4H position even while running.
The front drive gear shift fork has a shift fork spring to make a
smooth shift between the 4H position and the 2H position.
The case has an oil receiver and an oil protect plate to
provide proper lubrication even under the severe conditions of
use.

DS02 Driveshaft/Axle Transfer box 5

 Transfer control system

Instead of a transfer shift lever, the transfer position (2H, 4H

and 4L) is shifted automatically by operating the “2WD” switch,
“4WD” switch and “4WD-L” switch. The 4WD control module
operates the transfer shift actuator according to the “2WD”
switch, “4WD” switch and “4WD-L” switch operation. Also, the
transfer control system has 4WD indicator, 4WD low indicator
and warning buzzer in order to inform the transfer control
system condition.

The 4WD control module shifts the transfer to the selected shift
position (2H, 4H, or 4L) according to the signal from the “2WD”
switch, “4WD” switch or “4WD-L” switch. Figure 3: [A] 2WD/4WD selector switch [B] 4WD indicator

The 4WD control module controls the transfer shift actuator in

order to operate the shift fork shaft No.1. The 4WD control
module detects the position of the transfer shift actuator
motor by the signal from the transfer shift actuator limit switch.
Also, the 4WD control module detects each position (2H, 4H, or
4L) of the shift fork shaft No.1 installed to the transfer
assembly by the signals from the 4WD switch and the 4WD low
switch as follows

DS02 Driveshaft/Axle Transfer box 6

 Transfer components

[1] Input shaft

[2] Counter gear
[3] Hi/Lo Clutch sleeve
[4] Drive chain
[5] VSS ring
[6] Front output shaft
[7] Front clutch hub
[8] Front clutch sleeve
[9] Output gear
[10] Rear output shaft
[11] Stationery shift shaft
[12] Movable shift shaft
[13] 2 – 4 Shift fork
[14] Transfer 4WD switch
[15] HI/Lo shift fork
[16] Transfer L4 switch
[17] Transfer actuator

DS02 Driveshaft/Axle Transfer box 7

 Power transmission in the transfer

1) 2H position

The driving force from the transmission is input to the input

shaft and transmitted from the input shaft to the output gear
via the drive chain. At this time, because the output gear
and rear output shaft are fitted to each other, the driving
force is transmitted to the rear output shaft by the high-low
clutch sleeve. Note that because the front clutch hub is not
fitted to the front output shaft, the driving force is not
transmitted
to the front output shaft.

Figure 4

[1] Input shaft

[2] Counter gear
[3] Hi/Lo clutch sleeve
[4] Drive chain
[5] VSS sensor ring
[6] Front output shaft
[7] Front clutch hub
[8] Front clutch sleeve
[9] Output gear
[10] Rear output shaft
[11] Stationary shift shaft
[12] Movable shift shaft
[13] 2 – 4 shift fork
[14] Transfer 4WD switch (OFF)
[15] HI/Lo shift fork
[16] Transfer L4 switch (OFF)
[17] Transfer actuator
[18] 4WD/4L indicator

DS02 Driveshaft/Axle Transfer box 8

 2) 4H position

When the driver pushes the 4WD switch of the 2WD/4WD

selector switch and shifts into the 4H position, the motor of
the T/F actuator rotates and the movable shift shaft shifts in
the direction of arrow A. The pin that is installed on the 2-4
shift fork fits into the groove of the movable shift shaft and
moves the 2-4 shift fork in the same direction as the
movable shift shaft. As a result, the front clutch sleeve
moves in the direction of arrow B.

In the same way as when in the 2H position, the driving

force from the transmission is transmitted from the input
shaft to the rear output shaft via the drive chain. However,
because the front clutch hub is fitted to the front output
shaft by the front clutch sleeve, the driving force is also
transmitted to the front output shaft.

Figure 5

[1] Input shaft [2] Counter gear

[3] Hi/Lo clutch sleeve
[5] VSS sensor ring
[7] Front clutch hub
[9] Output gear
[11] Stationary shift shaft
[13] 2 – 4 shift fork
[15] HI/Lo shift fork
[17] Transfer actuator
[19] Pin
[4] Drive chain
[6] Front output shaft
[8] Front clutch sleeve
[10] Rear output shaft
[12] Movable shift shaft
[14] Transfer 4WD switch (ON)
[16] Transfer L4 switch (OFF)
[18] 4WD/4L indicator
[20] Groove

DS02 Driveshaft/Axle Transfer box 9

 3) 4WD-L position

When the driver pushes the 4WD-L switch of the 2WD/4WD

selector switch and shifts into the 4L position, the motor of
the T/F actuator rotates and the movable shift shaft shifts in
the direction of arrow A. At this time, the snap ring that is
installed on the movable shift shaft moves the high-low
shift fork in the same direction as the movable shift shaft.
As a result, the high-low clutch sleeve moves in the
direction of arrow B.
The driving force from the transmission is input to the input
shaft and transmitted to the output gear via the drive chain.
At this time, because the output low gear and rear output
shaft are fitted to each other by the high-low clutch sleeve,
the driving force is reduced with the output low gear via the
counter gear, and is transmitted to the rear output shaft.
In the same way as when in the 4H position, because the
front clutch hub is fitted to the front output shaft by the
front clutch sleeve, the driving force from the rear output
shaft is transmitted to the front output shaft.

Figure 6

[1] Input shaft [2] Counter gear

[3] Hi/Lo clutch sleeve
[5] VSS sensor ring
[7] Front clutch hub
[9] Output gear
[11] Stationary shift shaft
[13] 2 – 4 shift fork
[15] HI/Lo shift fork
[17] Transfer actuator
[19] Pin
[21] Output low gear
[4] Drive chain
[6] Front output shaft
[8] Front clutch sleeve
[10] Rear output shaft
[12] Movable shift shaft
[14] Transfer 4WD switch (ON)
[16] Transfer L4 switch (ON
[18] 4WD/4L indicator
[20] Groove
[22] Snap ring

DS02 Driveshaft/Axle Transfer box 10

 Transfer controller/4WD control module
The transfer controller performs control of the T/F actuator and
4WD/4L indicator based on the signals from the switches,
speed sensor and 4WD controller.
Input and output diagram
Figure 7: Input/output diagram for transfer controller
T/F shift control
The transfer controller operates the T/F actuator using the
switch operation that is input from the 2WD/4WD selector
switch on the instrument panel as the target shift position.
DS02 Driveshaft/Axle Transfer box
The T/F actuator is made up of a motor and 3 limit switches.
The movable contact point switches the limit switches
depending on the motor position. The transfer controller
detects the motor position from the ON/OFF condition of the
limit switches.
Figure 8: T/F actuator circuit diagram
Relationship of transfer shift position and switch
In addition, the T/F 4WD switch and T/F L4 switch that detect
the condition of the internal shift fork are installed on the
transfer unit. These turn ON and OFF in the different shift
positions (2H, 4H, 4L) as shown in the next table, inputting
the position of the movable shift shaft into the transfer
controller.
11
 2H → 4H shift control T/F shift control (2H → 4H) prohibition conditions
• T/F actuator limit switch: Position other than 2H
• Vehicle speed: Over 100 km/h

DS02 Driveshaft/Axle Transfer box 12

 4H → 2H shift control 4H → 4L shift control

T/F shift control (4H → 2H) prohibition conditions

• T/F actuator limit switch: Position other than 4H

DS02 Driveshaft/Axle Transfer box 13

 T/F shift control (4H → 4L) prohibition conditions 4L → 4H shift control

• T/F actuator limit switch: Position other than 4H

• Vehicle speed: Over 5 km/h
• AT selector position (AT vehicles): Range other than "N“
• Clutch switch (MT vehicles): OFF

T/F shift control (4L → 4H) prohibition conditions

• T/F actuator limit switch: Position other than 4L
• Vehicle speed: Over 5 km/h

DS02 Driveshaft/Axle Transfer box 14

 • A/T selector position (A/T vehicles): Range other than "N" The table in page 17 shows operation of the 4WD and 4WD-L
• Clutch switch (MT vehicles): OFF indicator under different conditions. Operation of the warning
buzzer is also included in the table. The warning buzzer is
integrated in the 4WD controller.

4WD Indicator control

The transfer controller turns the 4WD (1) and the 4L (2)
indicator in the combination meter on and off. While T/F shift
control is being performed, the indicator that matches the
input from the 2WD/4WD selector switch flashes in 0.5-second
intervals. When the T/F shift control is complete, the indicator
switches on or off.

DS02 Driveshaft/Axle Transfer box 15

DS02 Driveshaft/Axle Transfer box 16
 Description of limited shift operation

When the 4WD control module detects the following conditions

in the 4WD control system, the 4WD control module limits the
transfer shift operation as follows, and the limitation can be
canceled by turning ignition switch to “OFF” position.

DS02 Driveshaft/Axle Transfer box 17

 Basic tests of the 4WD components
1) T/F actuator check
1. Connect 2 new dry cell batteries in a series to
supply a total voltage of about 3 V.
2. As shown in the figure below, connect the positive side of
the power supply to terminal 1 of the T/F actuator and connect
the negative side to terminal 2. Check that the motor rotates
in direction A. Then connect the positive side of the power
supply to terminal 2 and the negative side to terminal 1. Check
that the motor rotates in direction B.
DS02 Driveshaft/Axle Transfer box
2) T/F actuator limit switch check
1. Follow the same procedure as the T/F actuator check to
connect the positive side of the power supply to terminal 1 of
the T/F actuator and connect the negative side to terminal 2.
Rotate the motor as far as possible in direction A (direction A
rotation limit).
2. Connect the positive side of the power supply to terminal 2
of the T/F actuator and connect the negative side to terminal
1. While slowly rotating the motor in direction B, check that
it passes through the following conduction conditions.
18
 3) 2WD/4WD selector switch check

Check that the conduction between the terminals is as

follows when the switches of the 2WD/4WD selector switch
are pressed.

DS02 Driveshaft/Axle Transfer box 19

 4) T/F 4WD switch and T/F L4 switch
check
Check that there is conduction when the projection on the
switches is pressed in the direction of the arrow, and that
there is no conduction when it is released.
DS02 Driveshaft/Axle Transfer box
4WD On-board diagnostic system
The 4WD control module has the following functions.
• When 4WD control module detects any malfunction, 4WD
indicator and 4WD low indicator flash continuously at the
same time, and 4WD control module sets DTC and comes
into fail-safe mode. For details of fail safe mode.
• The DTC stored in memory of the 4WD control module is
indicated by the 4WD indicator flashing in a specific
pattern.
3 Driving Cycle Detection Logic
The malfunction detected in the first and second driving cycle
is stored in 4WD control module memory (in the form of
pending DTC) but the 4WD indicator and 4WD low indicator
does not flashes at this time. It flashes at the third detection
of same malfunction also in the next driving cycle.
Pending DTC
Pending DTC means a DTC detected and stored temporarily at
2 driving cycle of the DTC which is adopted the 3 driving cycle
detection logic.
20
 DTC check

1) Turn ignition switch to ON position with engine stop.

2) While pushing 2WD switch (1) and 4WD switch (2), push
4WD-L switch (3) 5 times within 10 seconds.

[A] DTC No.: 12

[B] DTC No. 23
[C] Time
[a] 4WD indicator turned ON
[b] 4WD indicator turned OFF

3) Read flashing pattern of 4WD indicator which represents DTC

as shown in example below and write it down. When more than
2 DTCs are stored in memory, flashing for each DTC starts with DTC table
the smallest DTC number in increasing order.

The table below shows DTC’s that can be read out from the
4WD control module using the DTC check method above.

DS02 Driveshaft/Axle Transfer box 21

DS02 Driveshaft/Axle Transfer box 22
 Fail safe table

Clearing DTC’s

3) Perform DTC Check, and confirm that normal DTC (DTC 12)
1) Performing DTC check is displayed.
2) Keep pushing “2WD” switch, “4WD” switch and
“4WD-L” switch for 5 seconds or more.
At the end of step 2, DTC’s are cleared and 4WD
indicator indicates DTC No.: 12 (normal)

DS02 Driveshaft/Axle Transfer box 23

 Service information 6) Pour new specified oil unit oil level reaches bottom of oil
filler plug hole (3) as shown in figure.
7) Tighten new oil level/filler plug to specified torque
Transfer gear oil change
Gear oil specifications
1) Before changing or inspecting oil, be sure to stop engine
and lift vehicle horizontally.
2) With vehicle lifted up, check oil leakage. If leakage exists, API GL-4, It is high recommended to use API GL-4 75 W – 90
correct or repair it. gear oil.
3) Remove oil filler plug (2).
NB: Always refer to current service literature for the most
4) Remove drain plug (1), and drain old oil.
updated oil specifications:
5) Tighten new oil drain plug to specified torque.

DS02 Driveshaft/Axle Transfer box 24

 • A transfer case is installed in vehicles equipped
with the 4-wheel drive system.
• The transfer case distributes the driving force to
both the from the rear wheels.
• A mechanical lever or electronic switch is used to
select the different transfer mode.
• An actuator motor is installed in vehicles with
automatic shift 4WD system.
• Operation of the actuator motor and the 4WD
indicator light in the combination meter is
controlled by the 4WD control module based on
information from different inputs (sensors and
switches)
• Diagnostic Trouble Codes of the 4WD system can be
retrieved without the use of Suzuki SDT.
• The 4WD indicator light is used to read out fault
codes from the 4WD control module.

DS02 Driveshaft/Axle Transfer box 25

 Reference
C
The following abbreviations can be used in this CAN Controller Area Network
training manual CKP Crankshaft Position
CMP Camshaft Position
A CO Carbon Monoxide
A/B Air Bag CO2 Carbon Dioxide
ABDC After Bottom Dead Center CPP Clutch Pedal Position
ABS Anti-lock Brake System CPU Central Processing Unit
AC Alternating Current CVT Continuously Variable Transmission,
A/C Air Conditioning Continuously Variable Transaxle
A-ELR Automatic-Emergency Locking Retractor
A/F Air Fuel Ratio
D
ALR Automatic Locking Retractor
DC Direct Current
API American Petroleum Institute
APP Accelerator Pedal Position D/C Driving Cycle
A/T Automatic Transmission, Automatic Transaxle DLC Data Link Connector
ATDC After Top Dead Center DOHC Double Over Head Camshaft
ATF Automatic Transmission Fluid, Automatic DOJ Double Offset Joint
Transaxle Fluid DOT Department of Transportation
AWD All Wheel Drive DPF® Diesel Particulate Filter
API American Petroleum Industry DRL Daytime Running Light
DTC Diagnostic Trouble Code (Diagnostic Code)
B
D/C Driving Cycle
BARO Barometric Pressure
BBDC Before Bottom Dead Center
BCM Body electrical Control Module
BTDC Before Top Dead Center
B+ Battery Positive Voltage
BB+ Battery Positive Voltage for Backup

DS02 Driveshaft/Axle Transfer box 26

 E I
EBD Electronic Brake Force Distribution IAC Idle Air Control
ECM Engine Control Module IAT Intake Air Temperature
ECT Engine Coolant Temperature IMT Intake Manifold Tuning
ISC Idle Speed Control
ECU Electronic Control Unit
ISO International Organization for Standardization
EEPROM Electrically Erasable Programmable Read Only
Memory
J
EFE Heater Early Fuel Evaporation Heater
JIS Japanese Industrial Standards
EGR Exhaust Gas Recirculation J/B Junction Block
EGT Exhaust Gas Temperature J/C Junction Connector
ELR Emergency Locking Retractor
ENG A-Stop Engine Auto Stop Start L
EPS Electronic Power Steering L Left
ESP® Electronic Stability Program LCD Liquid Crystal Display LED Light Emitting Diode
EVAP Evaporative Emission LHD Left Hand Drive vehicle
LIN Local Interconnect Network
G LO Low
LSPV Load Sensing Proportioning Valve
GND Ground
GPS Global Positioning System
M
GL Gear libricant MAF Mass Air Flow
MAP Manifold Absolute Pressure
H Max Maximum
HVAC Heating, Ventilating and Air Conditioning MFI Multiport Fuel Injection
HC Hydrocarbons Min Minimum
HFC Hydro Fluorocarbon MIL Malfunction Indicator Lamp (“CHECK ENGINE”
HI High Light or “SERVICE ENGINE SOON” Light)
M/T Manual Transmission, Manual Transaxle
HO2S Heated Oxygen Sensor

DS02 Driveshaft/Axle Transfer box 27

 N T
NOx Nitrogen Oxides TCC Torque Converter Clutch
TCM Transmission Control Module
O
OBD On-Board Diagnostic system TCSS Traction Control Support System
OCM Occupant Classification Module TDC Top Dead Center
OCV Oil Control Valve TP Throttle Position
O/D Overdrive TPMS Tire Pressure Monitoring System
OHC Over Head Camshaft
TWC Three-Way Catalytic converter
O2S Oxygen Sensor

P U
PCM Powertrain Control Module UART Universal Asynchronous Receiver / Transmitter
PCV Positive Crankcase Ventilation USB Universal Serial Bus
PM Particulate Mater
PNP Park / Neutral Position
P/S Power Steering V
PSP Power Steering Pressure VFD Vacuum Fluorescent Display
VIN Vehicle Identification Number
R VSS Vehicle Speed Sensor
R Right
VVT Variable Valve Timing
RAM Random Access Memory
RHD Right Hand Drive Vehicle
ROM Read Only Memory W
RPM Engine Speed WU-OC Warm Up Oxidation Catalytic converter
WU-TWC Warm Up Three-Way Catalytic converter
S
SAE Society of Automotive Engineers
SDM Sensing and Diagnostic Module (Air Bag Controller, Other
Air bag Control Module) 2WD 2-Wheel Drive
SDT Smart Diagnostic Tester 4WD 4-Wheel Drive
SFI Sequential Multiport Fuel Injection
SI System International
Note: ESP is a trademark of Daimler AG
SOHC Single Over Head Camshaft
DPF® is a trademark of HJS Fahrzeugtechnik GmbH & Co KG and Suzuki is
SRS Supplemental Restraint System the trade mark licensee.

DS02 Driveshaft/Axle Transfer box 28

 Well done, you have now completed
the “DS02 Driveline/axle transfer”
online training course!

Please take the online exam

DS02 Driveshaft/Axle Transfer box 29