SUZUKI GRAND VITARA 1999 2.G Owners Manual

7E-8 DIFFERENTIAL (FRONT)
6) Position slit in each bush (2) as shown when press-fitting it.
Bush instillation position (angle “A”) :
45
° (slit alignment)
7) Position each bush to bracket as shown in the figure
Bush installation position (length “a”) :
3.0 mm (0.12 in.)
8) Tighten differential front mounting and bracket bolt to speci-
fied torque for reinstallation.
Tightening torque
Front mounting bolt (a) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
Front mounting bracket bolt (b) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Rear Mounting for Front Differential Carrier
REMOVAL AND INSTALLATION
1) Lift up vehicle and remove rear mounting bracket (3) by
removing rear mounting bolt (1) and rear mounting bracket
bolts (2).
2) Check mounting rubber for damage or deterioration and
replace as necessary.
3) Tighten rear mounting bolts (1) and rear mounting bracket
bolts (2) to specified torque for reinstallation.
Tightening torque
Rear mounting bolt (a) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
Rear mounting bracket bolts (b) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
1. Front mounting bracket L
3. Front mounting bracket R
1. Front mounting bracket R
2. Front mounting bracket L
1, (a)
2, (b)
3

DIFFERENTIAL (FRONT) 7E-9
Front Differential Assembly
DISMOUNTING
1) Lift up vehicle and drain oil.
2) Disconnect air hose and breather hose from differential
housing.
3) Before removing propeller shaft, give match marks (1) on
joint flange and propeller shaft as shown in the figure.
4) Remove propeller shaft flange by removing its 4 bolts and
suspend it with cord or the like.
5) Remove bolts (1) for left mounting bracket and bolts and
nuts (2) for drive shaft flange to set left side of differential
free.
6) Remove bolts (1, 2) and rear mounting bracket (3).
7) Remove bolts (4) and rear mounting bracket No.2 (5).
8) With differential housing assembly held with transmission
jack, remove front mounting bracket (2) bolts (1) on right end
of housing (3). NOTE:
If pull out propeller shaft, transfer oil must be drained
before pulling out.
4 1
2
5
3

7E-10 DIFFERENTIAL (FRONT)
9) Using 2 large screwdrivers (4) as levers, pull out right side
drive shaft joint (1) from differential (2) and dismount housing
assembly from vehicle.
REMOUNTING
For remounting, reverse dismounting procedure and use the fol-
lowing tightening torque.
Tightening torque
Front drive shaft flange bolts (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Propeller shaft flange bolts (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Front mounting bracket bolts (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Rear mounting bracket bolts(a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Rear mounting bolt (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
Rear mounting bracket No.2 bolts (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
After tightening all fasteners properly, fill hypoid gear oil as speci-
fied and check tightening of plugs with specification.CAUTION:
During above work, use care not to cause damage to
drive shaft boot.
(b) (b)
(a)

DIFFERENTIAL (FRONT) 7E-11
Unit Repair
Refer to the same section of “UNIT REPAIR MANUAL” mentioned in “FOREWORD” of this manual.
Tightening Torque Specification
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Front mounting bolts 85 8.5 61.5
Front mounting bracket bolts 50 5.0 36.5
Front drive shaft flange bolts 50 5.0 36.5
Propeller shaft flange bolts 50 5.0 36.5
Rear mounting bolt 85 8.5 61.5
Rear mounting bracket bolts 50 5.0 36.5
Rear mounting bracket No.2 bolts 85 8.5 61.5
09918-18110 09951-16080 09951-26010
Air pressure regulator Bearing installer Bush remover plate

7E-12 DIFFERENTIAL (FRONT)

DIFFERENTIAL (REAR) 7F-1
7F
SECTION 7F
DIFFERENTIAL (REAR)
CONTENTS
General Description ........................................ 7F-2
Diagnosis ......................................................... 7F-2
Diagnosis Table ............................................ 7F-2
On-Vehicle Service.......................................... 7F-3
Precaution for Maintenance Service ............. 7F-4
Differential Gear Oil Change ......................... 7F-4
Rear Differential Assembly ............................ 7F-5
Dismounting .............................................. 7F-5
Remounting ............................................... 7F-5
Unit Repair ....................................................... 7F-6Disassembling Unit ....................................... 7F-6
Component Inspection .................................. 7F-9
Sub-Assembly Adjustment and Reassembly 7F-9
Differential carrier .................................... 7F-10
Differential case ...................................... 7F-10
Differential side bearing .......................... 7F-12
Drive bevel pinion.................................... 7F-13
Assembling Unit .......................................... 7F-17
Tightening Torque Specification ................. 7F-20
Required Service Material ............................ 7F-20
Special Tool ................................................... 7F-21

7F-2 DIFFERENTIAL (REAR)
General Description
The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle. It is set in the conven-
tional type axle housing.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine
parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between
bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Diagnosis
Diagnosis Table
Condition Possible Cause Correction
Gear noiseDeteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between drive bevel pin-
ion and gearAdjust as prescribed.
Improper tooth contact in the mesh between
drive bevel pinion and gearAdjust or replace.
Loose drive bevel gear securing bolts Replace or retighten.
Damaged differential gear(s) or differential pin-
ion(s)Replace.
Bearing noise(Constant noise) Deteriorated or water mixed
lubricantRepair and replenish.
(Constant noise) Inadequate or insufficient
lubricantRepair and replenish.
(Noise while coasting) Damaged bearing(s) of
drive bevel pinionReplace.
(Noise while turning) Damaged differential side
bearing(s) or axle bearing(s)Replace.
Oil leakageClogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.

DIFFERENTIAL (REAR) 7F-3
On-Vehicle Service
1. Universal joint flange 9. Differential carrier assembly 17. Bearing adjuster 25. Bolt
2. Hypoid gear set 10. Differential pinion 18. Lock plate 26. Bolt
3. Bevel pinion spacer
Apply thread lock cement
99000-32110 referring to
“DIFFERENTIAL CASE” in
this section.11. Differential gear 19. Pinion shaft No.2 27. Differential case screw :
Apply thread lock
cement 99000-32110 to
thread part of bolt.
4. Shim 12. Pinion shaft No.1 20. Pinion joint Do not reuse.
5. Rear bearing 13. Differential left case 21. Spring washer Tightening torque
6. Front bearing 14. Differential right case 22. Washer Apply differential oil.
7. Oil seal :
Apply grease 99000-25010
to oil seal lip.15. Thrust washer 23. Bevel gear bolt :
Apply thread lock
cement 99000-32110
to thread part of bolt.
8. Flange nut :
After tightening nut so as
rotation torque of bevel pin-
ion shaft to be in specified
value, caulk nut securely.16. Differential side bearing 24. Bolt

7F-4 DIFFERENTIAL (REAR)
Precaution for Maintenance Service
•When having driven through water, check immediately if
water has entered (if so, oil is cloudy). Water mixed oil must
be changed at once.
•Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status of
breather hoses.
Differential Gear Oil Change
1) Before oil change or inspection, be sure to stop engine and
lift up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,
correct its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain plug (3) and level/filler plugs (2) to specification.
“A” : Sealant 99000-31110
Tightening torque
Differential oil level/filler plug (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Differential oil drain plug (b) :
28 N·m (2.8 kg-m, 20.5 lb-ft)
Hypoid gear oil :
API GL-5, SAE 75W-85, 80W-90 or 90
Oil capacity :
2.5 liters (5.3/4.4 US/Imp. pt.) NOTE:
Hypoid gear oil must be used for differential.
It is highly recommended to use SAE 80W-90 viscosity.
1. Breather hose

DIFFERENTIAL (REAR) 7F-5
Rear Differential Assembly
Dismounting
1) Lift up vehicle and drain oil from rear differential housing.
2) Remove rear brake drums and pull out right and left rear axle
shafts. (Refer to “REAR AXLE SHAFT REMOVAL” of Section
3E.)
3) Before removing propeller shaft, give match marks (1) on
joint flange and propeller shaft as shown.
4) Remove propeller shaft by removing its flange bolts and
nuts.
5) Remove differential assembly by removing its 8 fastening
bolts (1).
Remounting
1) Clean mating surfaces of rear axle and differential assembly
and apply sealant to axle side evenly.
“A” : Sealant 99000-31110
2) Install differential assembly to axle and fix it with bolts (1)
tightened to specified torque.
Tightening torque
Differential carrier bolts (a) :
55 N·m (5.5 kg-m, 40.0 lb-ft)