SUZUKI GRAND VITARA 1987 Service Repair Manual

4WD Gear Shift Lever
Check lower end of gear shift lever where gear
shift fork shaft contacts @ for wear and any
kind of damage. Worn or damaged shift lever
must be replaced with new one.
14-8. REASSEMBLY
NOTE:
l All parts to be used in reassembly must be
perfectly clean.
l Oil or grease sliding and rubbing surfaces of
transfer components just before using them
in reassembly with gear oil and SUZUKI
SUPER GREASE A (99000-25010).
l Oil seals, “0” rings, gaskets and similar sealing
members must be in perfect condition. For
these members, use replacement parts in
stock.
l Tightening torque is specified for important
fasteners- mainly bolts - of transfer and
other components. Use torque wrenches and
constantly refer to specified data given in
P. 14-23.
Fig. 14-42
Input Shaft
Press-fit bearings onto both sides of input shaft
by using bearing installer (special tool).
Bearing installer (A) : (09913-84510)
(A)
Fig. 14-43
14-14

Output Rear Shaft
Install following parts onto shaft in such order
and directions as prescribed in the figure.6 9
1. Circlip
2.Hub
3.Bearing4.Bearingouter ring
5. Thrust washer
6.Outputhigh gear7.Bearing(long)
8. Output rear shaft
9.Sleeve
10.Bearing (short)
11.Outputlowgaar12.Thrust washer
13. Speed meter drive gear
14.Bearing15.Retainer
Fig. 14-44
1) After installing bearing (long), high gear and
thrust washer, press-fit bearing 1. and then
hub @ by using bearing installer (special
tool).
Bearing installer (A) : (0991384510)
Fig. 14-45
2) Fit circlip @ securely into groove in shaft.
Fig. 14-46
3) After installing sleeve, bearing (short), low
gear and thrust washer, press-fit speedometer
drive gear by using bearing installer (special
tool).
Bearing installer (A) : (09913-84510)
(A)
Fig. 14-47
4) Press-fit bearing @ and the retainer @ by
using bearing installer (special tool).
Bearing installer (A) : (0991384510)
Fig. 14-4814-15

Shim Adjustment of Input and Output Shafts
Clearance in thrust direction of both input and
output shafts is adjusted by putting shims
between input shaft rear bearing and rear case
for input shaft and between output shaft rear
bearing and rear case for output shaft.
As thrust clearance is specified as follows
determine shim thickness to meet specification
according to the following procedures.
Thrust clearance0.05 - 0.15 mm
specification(0.002 - 0.006 in.)
[Input shaft]
1) Take measurement “A” of rear case as shown
in figure below by using depth gauge,
2) Take measurement “6” of center case with
bearing circlip installed.
3) Take measurement“C” (between bearing
inner races) of input shaft with bearings
installed, by using micrometer.
NOTE:
l Before measuring, make sure that each bearing
is free from abnormal noise or resistance by
spinning its outer race.
l Each measurement in above steps 1) to 3)
must be taken accurately in careful manner,
If shim thickness is determined based on
rough measurement, clearance of each shaft in
thrust direction will not satisfy specification.
And improper clearance may cause oil leakage,
broken bearing and abnormal noise.
l Take the same measurement at 3 to 4 diffe-
rent positions and use their mean.
6
1.1.Center caseCenter case5.5.Bearing circlipBearing circlip
2.2.Rear caseRear case6.6.GasketGasket
3.3.Input shaftInput shaft7.7.Gasket thicknessGasket thickness4. Output shaft4. Output shaft(0.3 mm or 0.012 in)(0.3 mm or 0.012 in)
Fig.Fig.14-48-14-48-11
4) Using measurements obtained in steps 1) to 3)
and equation described below, calculate shim
thickness which is necessary for proper
thrust clearance.
Thrust clearance = (“A” + “B” + Gasket
thickness) - “C”
As the above equation holds for thrust
clearance and gasket thickness is specified as
0.3 mm and thrust clearance as 0.05 to 0.15
mm, shim thickness is calculated by the
following equation.
Shim thickness = (“A” + “B” + 0.3 ) -
(“C” + 0.05 - 0.15)
[Example]
Supposing A, B and C are as follows;
A = 81.35 mm (3.203 in.)
B = 35.70 mm (1.405 in.)
C = 117.05 mm (4.608 in.)
Shim thickness = (81.35 + 35.70 + 0.3) -
(117.05 + 0.05 N 0.15)
= 117.35- 117.10~ 117.20
= 0.25 - 0.15
In this case, use of 0.15 to 0.25 mm (0.006 to
0.009 in) thick shim(s) will ensure specified
thrust clearance which is 0.05 to 0.15 mm
(0.002 to 0.006 in). Therefore 2 pieces of
0.1 mm (0.004 in) thick shim should be
selected in available shims below to satisfy
thickness.
14-16
Fig. 14-48-1

5) When shim thickness is determined, select
proper shim(s) from among the following
shims and use it (them) between input shaft
rear bearing and rear case when matching
center case and rear case.
Available shim0.1, 0.3,0.5 mm
size (thickness)(0.004,0.012,0.020 in.)I
[Output shaft]
Just as with input shaft, take measurements of
“A’ “, “B’ ” and “C’ ” as indicated in Fig.
14-48-1, calculate shim thickness and install
proper shim(s) between output shaft rear bearing
and rear case when matching center case and
rear case.
1. Shim for input shaft2. Shim for output shaft
fig. 14-48-2
14-17
Fig. 14-48-2

Rear Case
1) Install oil seal in rear case and apply grease
to oil seal lip.
Center Case
1) Install input shaft front bearing circlip and
oil seal in center case.
Snap ring pliers @ : (09900~6108)
Fig. 14-49
Fig. 14-51
2) Install counter shaft thrust washer to rear
case, bringing its face without depressions
against case and fit its bent portion securely
into groove in case.
NOTE:
Apply ample amount of grease to both surfaces
of washer so as to lubricate sliding surfaces and
prevent washer from moving out of place or
slipping off.
Fig. 14-50
2) Install input shaft to center case.
Fig. 14-52
3) After greasing 0 ring on counter shaft,
insert shaft into center case and secure
shaft with lock plate and bolt.
Fig. 14-53
Fig. 14-50
14-18
Fig. 14-53
Fig. 14-52

4) Install the counter shaft thrust washer to
center case. For installation, apply ample
amount of grease to both faces of the washer
so as to lubricate sliding surfaces and prevent
it from moving out of place or slipping off
and bring its face without depressions against
center case, and fit its bent portion into
groove in case securely.
Fig. 14-54
5) Install needle roller bearings, spacer and
counter gear on counter shaft.
Fig. 14-55
6) Install output shaft assembly to center case.
Fig. 14-56
7) When installing front drive shift shaft and
reduction shift shaft in center case, install
spring 0, ball 0, shaft 0, ball @, shaft
0, ball 8, spring 0 and plug 8. in that
order.
d 18-3ON.m
Fig. 14-57(1.8 - 3.0 kg-m 1(13.5 - 21.5 lb-ft)
8) Fit forks on shift shafts and lock them
with spring pins. Forks should be fitted in
correct direction according to below figure.
Fig. 14-58
14-19
Fig. 14-54
Fig. 14-55
Fig. 14-58
Fig. 14-57
Fig. 14-56
14-19

Center and Rear Cases
1) Check center case (or rear case) to ensure
that it is provided with 2 dowel pins 0.
Fig. 14-59
2) Put gasket on center case. Bring rear case
and center case into match and apply
uniform force gradually all around rear case
with a plastic hammer. Tighten center case
securing bolts to specified torque.
NOTE:
l Matching must be made carefully so as not to
move countershaft thrust washers out of place.
l Be sure to install shims determined in previ-
ous item“Shim Adjustment of Input and
Output Shafts”between input shaft rear
bearing and rear case and between output
shaft rear bearing and rear case.
Fig. 14-61
Fig. 14-62
3) Apply grease to output front shaft rear
bearing.
Fig. 14-60
Fig. 14-63
14-20

Front Case
1) Install bearing, circlip and oil seal to front
case. Apply grease to oil seal lip and install
output front shaft using bearing installer
(special tool).
Bearing installer (A) : (09913-76010)
Fig. 14-64
2) Put gasket on center case.
3) Check front case to ensure that it is provided
with 2 dowel pins.
Fig. 14-65
4) Install front case to center case.
Fig. 14-66
5) When installing speedometer driven gear
and its gear case in rear case, apply grease to
0 ring and oil seal lip, and align bolt holes
in rear case and driven gear case.
Fig. 14-67
6) Install 4WD ball and switch. Then clamp
switch lead wire properly.
/1.6 - 2.3 kgm
Fig. 14-68 (12.0 - 16.5 lb-h)
14-21

7) Install propeller shaft flanges and tighten
nuts to specified torque and talk the nuts.
8) Upon completion of entire assembly work,
install transfer in chassis body in reverse
sequence of removal. Pour gear oil into
transfer gear box.
Refer to information given in next oil and
oil capacity for oil to be used and specified
amount.
NOTE:
When installing oil filler and drain plugs to
transfer case, apply sealant (SUZUKI BOND
No.1215, 99000-31110) to thread part of plug.
14-9. MAINTENANCE SERVICES
Oil Level
Oil level must be checked with car held in
horizontal position in both front to rear and side
to side directions.
Oil level plug and oil filler plug are one and the
same as shown in figure.
If oil flows out of filler plug hole or if oil level is
found up to hole when plug is removed, amount
of oil is appropriate. Replenish oil if noted as
insufficient.
Oil and Oil Capacity
Whenever car is lifted up for any service includ-
ing oil change,make sure to check around
transfer gear box for oil leakage. Correct defects,
if any, and change or refill oil.
Transfer oil capacity0.8 litre (1.7/l .4 US/Imp. pt)
Transfer oilGear oil SAE 8OW-90,
specification75W-80 or 75W-90
It is highly recommended to use SAE 75W-90
gear oil.
For viscosity chart, refer to P. 1-20.
@ : Oil drain plug
Fig. 14-70@ : Oil filler & level plug
14-22

14-10. TIGHTENING TORQUE
Counter shaft lock
Universaljoint flange
Oil filler and drain
plug
Cross joint bolt & nut
Transfer mounting nut
Transfer mounting
bracket bolt
Universal joint
flange nut
Counter shaft lock
plate bolt
Center case bolt
Front case bolt
Fastening parts
14-23