SUZUKI GRAND VITARA 1987 Service Repair Manual

4-Wheel Drive LOW (All-Wheel Drive on LOW)
Gear shift control lever position
4-wheeldrive LOW
2H
5l
Front shifterforkactuates front clutch to couple
rear shaft to front shaft; and rear shifter fork
actuates rear clutch to couple “low” gear to rear
shaft. Front shaft and rear shaft run together on From
LOW.
To front whe
Fig. 14-4
14-3. GEAR RATIO DATA
Gear
Reduction
Rear-wheel drive
41/44 - 62/41
1.409
All-wheel drive high
41/44 62/41-
1.409
All-wheel drive low
41/44 - 56/23
2.268
14-4

14-4. TRANSFER SERVICES NOT REQUIRING TRANSFER REMOVAL
Following parts or components do not require transfer removal to receive services (replacement, inspec-
tion) :
Part or ComponentNature of Service
1. Universal-joint yoke flangesReplacement or inspection
2. Front drive shift shaft forkReplacement or inspectionI
3. Transfer output front shaft oil seal
4. Transfer output front shaft bearing
5. Transfer output front shaft
Replacement or inspection
Replacement
Replacement
6. Transfer front caseReplacement
7. Front drive clutch hubReplacement or inspection
8. Front drive clutch sleeveReplacement or inspection
9. Transfer input shaft oil sealReplacement
10. 4WD indicator light switchReplacement or inspection
11. Speedometer driven gearReplacement or inspection
12. Gear shift control leverReplacement or inspection
13. Gear shift control boot No. 1, No. 2Replacement
14. Gear shift control lever spring seatReplacement or inspection.
14-5

14-5. REMOVAL
1) Lift up car and remove securing bolts from
each universal-joint flange connection to
sever 3 propeller shafts from transfer gear
box.
Fig. 14-5
2) Remove clamp @ and boot @ from transfer
gear box.
Fig. 14-7
4) Drain out oil from gear box by loosening
its drainplug.
Fig. 14-8
5) Disconnect speedometer drive cable from
transfer gear box.
Transfer‘gear case
Fig. 14-6
3) Twist control lever guide counterclockwise
while pushing it down; this will permit lever
to be removed from gear box.
14-6
Fig. 14-8
Fig. 14-9

6) Disconnect 4WD switch lead wire at coupler.
7) Remove 3 mounting nuts securing gear box
to chassis, and take down gear box.

14-7
Fig. 14-11

14-6. DISASSEMBLY
Universal-Joint Yoke Flanges
There are 3 flanges to be removed: one from
input shaft and other from output front and rear
shafts. Lock flange so that it will not turn, and
loosen and remove nut holding flange to the
shaft. Draw off flange.
Fig. 14-12 @ Special tool (09930401131
Speedometer Driven Gear
Loosen speedometerdriven gear case bolt
and remove speedometer driven gear case with
gear.
Transfer Front Case
Remove the indicator light switch from front
case.
NOTE:
Use care not to lose switch ball. This ball is
larger than interlock ball and locating balls.
Fig. 14-16
Remove bolts securing transfer front case,
and take off case.
By tapping output front shaft with a plastic
hammer,remove output front shaft from
front case.
Fig. 14-18
Fig. 14-15
14-8
Fig. 14-17

After removing oil seal, remove circlip and drive
bearing out of front case by using bearing
installer (special tool).
Bearing installer 0 : (09913-76010)
Fig. 14-19
Transfer Center Case
Remove bolts fastening center case and rear
case together.
Do not loosen bolt @ at this point.
By tapping rear case and output rear shaft with.
a plastic hammer, separate center and rear case.
Fig. 14-22
Given below are procedures for disassembling
component parts of center case as separted from
rear case.
1) Loosen gear shift locating spring plug and
take out spring and locating ball.
Fig. 14-23
14-9
Fig. 14-20
Fig. 14-21

2) Using spring pin remover (special tool), drive
2 spring pins out of front drive shift shaft
@ and reduction shift shaft 0.
Spring pin remover @ : (09922-85811).
Fig. 14-24
3) Remove forks and shift shafts.
NOTE:
At this time, locating ball and spring will jump
out of hole, use care not to lose them.
Fig. 14-25
4) Hammer output rear shaft with a plastic
hammer to drive it out of center case.
5) Pull out counter gear,
Remove counter shaft
loosening counter shaft
bearings and spacer.
from center case by
lock plate bolt.
Fig. 14-27
6) Remove input shaft from center case by
hammering thick part of case or input
shaft center with a plastic hammer.
Fig. 14-28
14-10
Fig. 14-26

7) Remove output shaft rear bearing and
retainer together by using bearing puller.
After removing bearing, speedometer drive
gear, thrust washer, output low gear and
needle roller bearing can be removed.
Fig. 14-29
8) Remove front drive clutch hub circlip and
pull clutch hub off shaft by using bearing
puller and puller attachment (special tool A).
NOTE:
Use care to prevent damage to needle roller
bearing in output rear shaft when removing
clutch hub.
/(A) 0992638010
Fig. 14-30
9) Remove front bearing by using bearing
puller and puller attachment (special tool
A).
NOTE:
Use care to prevent damage to needle roller
bearing in output rear shaft while bearing is
being removed.
(A) 09926-58010
Fig. 14-31
10) When input shaft is removed or center case
and rear case are separated, input shaft
bearings may come off. In such a case,
bearings can be removed from shaft by using
bearing puller.
**ita“+
Fig. 14-32
14-11

11) When input shaft is removed, front bearing
may be left in case. In this case, after remov-
ing oil seal and circlip, bearing can be taken
out of case by using bearing installer (special
tool).
Bearing installer @ : (09913-75810)
Fig. 14-33
Transfer Rear Case
1) When center case and rear case are separated,
input shaft may be left in rear case. In this
case, remove input shaft from rear case by
hammering thick part of case with a plastic
hammer.
Fig. 14-34
14-7. INSPECTION OF COMPONENTS
Gear Teeth
Inspect gear teeth 0, internal teeth of rear
clutch sleeve @ and clutch teeth of gear 3. for
wear, cracking, chipping and other
malcondition. Replace gear or sleeve as necessary.
Fig. 14-35
Fig. 14-36
Locating Spring
Check each shifter fork shaft locating spring for
strength by measuring its free length. If length is
noted to be less than service limit, replace it.
Free length of
locating spring
14-12

Fig. 14-37
Bearings
Check each bearing by spinning its outer race by
hand to “feel” smoothness of rotation. Replace
bearing if noted to exhibit sticking, resistance
or abnormal noise when spun or rotated by
hand.
Fig. 14-38
Side Clearance of Gears
With gear, bearing and thrust washer installed
on shaft, check for side clearances of gears.
If clearance exceeds service limit, replace thrust
washer.
I
Side clearance
of gear StandardService limitI
outputlow gear0.175 - 0.325mm0.7mm
gearshigh gear(0.007 - 0.012in)(0.027in)
Fig. 14-40 Output low gear
Gear Shift Shafts
Check each part as indicated in below figures for
uneven wear. Replace defective parts.
Fig. 14-41
14-13
Fig. 14-39 Output high gear