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SUZUKI SQ416 SQ420 SQ625 UNIT REPAIR MANUAL – PDF DOWNLOAD
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The “Suzuki SQ416 SQ420 SQ625 Unit Repair Manual” provides specific instructions for repairing components of these models. Essential for technicians, ensuring precise unit repairs for optimal performance.
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Description
SUZUKI SQ416 SQ420 SQ625 UNIT REPAIR MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI SQ416 SQ420 SQ625 UNIT REPAIR MANUAL – PDF DOWNLOAD
Language : English
Pages : 214
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI SQ416 SQ420 SQ625 UNIT REPAIR MANUAL – PDF DOWNLOAD
Manual List............................................................................... 0 IMPORTANT................................................................................. 1 WARNING/CAUTION/NOTE.................................................................. 1 FOREWORD.................................................................................. 2 TABLE OF CONTENTS......................................................................... 3 SECTION 7A................................................................................ 4 GENERAL DESCRIPTION................................................................... 5 COMPONENTS........................................................................ 5 UNIT DISASSEMBLY...................................................................... 7 GEAR SHIFT LEVER CASE (4WD MODEL)................................................. 7 GEAR SHIFT LEVER CASE (2WD MODEL)................................................. 8 TRANSMISSION UNIT................................................................. 8 SUB-ASSEMBLY...................................................................... 11 INPUT SHAFT................................................................... 11 MAIN SHAFT.................................................................... 12 UPPER CASE AND SHIFTER........................................................ 14 COMPONENT INSPECTION.................................................................. 14 COUNTER SHAFT AND MAIN SHAFT INNER PARTS.......................................... 14 LOW AND REVERSE SCISSORS GEAR ASSEMBLIES (IF EQUIPPED)........................ 16 UPPER CASE AND SHIFTER............................................................ 17 REAR CASE......................................................................... 17 UNIT ASSEMBLY......................................................................... 18 GEAR SHIFT LEVER CASE (4WD MODEL)................................................. 18 GEAR SHIFT LEVER CASE (2WD MODEL)................................................. 20 SUB ASSEMBLY...................................................................... 22 MAIN SHAFT.................................................................... 22 COUNTER SHAFT................................................................. 25 UPPER CASE AND SHIFTER........................................................ 27 TRANSMISSION UNIT................................................................. 30 TIGHTENING TORQUE SPECIFICATION....................................................... 33 REQUIRED SERVICE MATERIAL............................................................. 33 SPECIAL TOOL.......................................................................... 34 SECTION 7A1............................................................................... 36 GENERAL DESCRIPTION................................................................... 37 COMPONENTS........................................................................ 37 UNIT DISASSEMBLY...................................................................... 40 GEAR SHIFT LEVER CASE............................................................. 40 TRANSMISSION UNIT................................................................. 40 SUB-ASSEMBLY...................................................................... 49 INPUT SHAFT ASSEMBLY.......................................................... 49 MAIN SHAFT ASSEMBLY........................................................... 49 COUNTER SHAFT & REVERSE IDLE GEAR............................................. 50 INPUT SHAFT BEARING RETAINER AND OIL SEAL..................................... 51 TRANSMISSION REAR CASE........................................................ 51 COMPONENTS INSPECTION................................................................. 52 SUB-ASSEMBLY...................................................................... 52 INPUT SHAFT ASSEMBLY.......................................................... 52 MAIN SHAFT ASSEMBLY........................................................... 53 COUNTER SHAFT AND REVERSE IDLE GEAR........................................... 55 UNIT ASSEMBLY......................................................................... 57 GEAR SHIFT LEVER CASE............................................................. 57 SUB-ASSEMBLY...................................................................... 58 INPUT SHAFT ASSEMBLY.......................................................... 58 MAIN SHAFT ASSEMBLY........................................................... 59 COUNTER SHAFT AND REVERSE IDLE GEAR........................................... 63 INPUT SHAFT BEARING RETAINER AND OIL SEAL..................................... 64 TRANSIMISSION REAR CASE....................................................... 64 TRANSMISSION INTERMEDIATE CASE AND FRONT CASE (LOCATION OF KNOCK AND PLUG).... 65 TRANSMISSION UNIT................................................................. 66 TIGHTENING TORQUE SPECIFICATION....................................................... 77 REQUIRED SERVICE MATERIAL............................................................. 77 SPECIAL TOOL.......................................................................... 78 SECTION 7B1............................................................................... 80 GENERAL DESCRIPTION................................................................... 81 TORQUE CONVERTER DIAGNOSIS............................................................ 82 STATOR ASSEMBLY FREEWHEELS........................................................ 82 STATOR ASSEMBLY REMAINS LOCKED UP................................................. 82 DO NOT REPLACE CONVERTER FOR FOLLOWING CONDITIONS :............................... 82 UNIT REPAIR........................................................................... 83 PRECAUTIONS....................................................................... 83 PART INSPECTION AND CORRECTION TABLE.............................................. 83 UNIT DISASSEMBLY.................................................................. 84 SUB-ASSEMBLY REPAIR............................................................... 89 OIL PUMP...................................................................... 89 OVERDRIVE (PLANETARY GEAR SIDE)............................................... 92 OVERDRIVE (CASE SIDE)......................................................... 96 FORWARD CLUTCH................................................................ 99 DIRECT CLUTCH.................................................................103 CENTER SUPPORT................................................................107 PLANETARY GEARS AND OUTPUT SHAFT..............................................113 VALVE BODY ASSEMBLY...........................................................117 FRONT UPPER VALVE BODY........................................................122 REAR UPPER VALVE BODY.........................................................126 UNIT ASSEMBLY.....................................................................133 BEARING AND RACE INSTALLATION DIAGRAM.........................................145 TIGHTENING TORQUE SPECIFICATION.......................................................146 REQUIRED SERVICE MATERIAL.............................................................146 SPECIAL TOOL..........................................................................147 SECTION 7D................................................................................148 GENERAL DESCRIPTION...................................................................149 COMPONENTS........................................................................149 UNIT REPAIR...........................................................................151 DISASSEMBLY.......................................................................151 COMPONENT INSPECTION..............................................................157 ASSEMBLY..........................................................................158 TIGHTENING TORQUE SPECIFICATION.......................................................170 REQUIRED SERVICE MATERIAL.............................................................170 SPECIAL TOOL..........................................................................171 SECTION 7E................................................................................174 GENERAL DESCRIPTION...................................................................175 COMPONENT.........................................................................175 UNIT REPAIR...........................................................................176 DISASSEMBLY UNIT..................................................................176 COMPONENTS INSPECTION.............................................................179 DIFFERENTIAL LEFT CASE........................................................179 FREE AXLE HUB.................................................................180 ACTUATOR......................................................................180 SUBASSEMBLY ADJUSTMENT AND REASSEMBLY.............................................181 DIFFERENTIAL CARRIER..........................................................181 DIFFERENTIAL CASE.............................................................181 DRIVE BEVEL PINION............................................................183 ASSEMBLY UNIT.....................................................................186 TIGHTENING TORQUE SPECIFICATION.......................................................191 REQUIRED SERVICE MATERIAL.............................................................192 SPECIAL TOOL..........................................................................192 SECTION 7F................................................................................194 GENERAL DESCRIPTION...................................................................195 UNIT REPAIR...........................................................................196 DISASSEMBLING UNIT................................................................196 COMPONENT INSPECTION..............................................................199 SUB-ASSEMBLY ADJUSTMENT AND REASSEMBLY............................................199 DIFFERENTIAL CARRIER..........................................................199 DIFFERENTIAL CASE.............................................................199 DIFFERENTIAL SIDE BEARING.....................................................202 DRIVE BEVEL PINION............................................................203 ASSEMBLING UNIT...................................................................207 TIGHTENING TORQUE SPECIFICATION.......................................................211 REQUIRED SERVICE MATERIAL.............................................................211 SPECIAL TOOL..........................................................................212 Bookcover................................................................................. 0
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