SUZUKI GRAND VITARA 1999 2.G Owners Manual

7F-6 DIFFERENTIAL (REAR)
3) Install propeller shaft to joint flange aligning match marks
and torque flange nuts to specification. Apply thread lock
cement to thread part of bolt if reused.
“A” : Cement 99000-32110
Tightening torque
Propeller shaft flange nuts (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
4) Install right and left rear axle shafts and drums.
(Refer to “REAR AXLE INSTALLATION” of Section 3E and
rear brake drum installation of Section 5.)
5) Install wheels.
6) Fill hypoid gear oil as specified and tighten plug to specifica-
tion.
7) Lower lift.
Unit Repair
Disassembling Unit
1) Hold differential assembly securely and put identification
marks on differential side bearing caps (6).
2) Take off differential side bearing lock plates (4) and differen-
tial side bearing caps (6) by removing their bolts and then
take out bearing adjusters (5), side bearing outer races and
drive bevel gear with differential case.
3) Remove drive bevel gear (hypoid gear), differential gears,
differential pinions and pinion shafts.
a) With aluminum plates (2) placed on vise first, grip differen-
tial case with it and remove drive bevel gear (hypoid gear)
(3) by removing its bolts (1).
1. Differential carrier
2. Drive bevel gear assembly
3. Differential case
A: Identification mark
1
3
2

DIFFERENTIAL (REAR) 7F-7
b) Remove differential left case (2) from differential right case
(1).
c) Remove pinion shafts, differential gears, washers, differen-
tial pinions, spring washers, thrust washers.
4) Using special tools, pull out differential side bearings (1).
Special tool
(C) : 09913-85230
(D) : 09913-61510
5) Remove drive bevel pinion (hypoid gear) assembly.
a) Hold universal joint flange with special tool and then
remove flange nut by using power wrench (4 - 10 magnifica-
tion) (2).
Special tool
(E) : 09922-66021
2
1
1. Socket wrench

7F-8 DIFFERENTIAL (REAR)
b) Make mating marks (1) on drive bevel pinion and compan-
ion flange.
c) Remove companion flange from drive bevel pinion. Use
special tool if it is hard to remove.
Special tool
(F) : 09913-65135
d) Remove drive bevel pinion with rear bearing, shim and
spacer from carrier.
If it is hard to remove, screw an used nut into drive bevel
pinion and hammer on that nut with a plastic hammer but
never directly on drive bevel pinion.
e) Remove drive bevel pinion rear bearing (2) by using bear-
ing puller (3) and press. CAUTION:
Don't make mating mark on the coupling surface of the
flange.
1. Drive bevel pinion

DIFFERENTIAL (REAR) 7F-9
6) Using a hammer and brass bar (1), drive out front bearing
outer race with bearing (2) and oil seal (3).
7) Drive out rear bearing outer race in the same way as in the
step 6).
Component Inspection
•Check companion flange for wear or damage.
•Check bearings for wear or discoloration.
•Check differential carrier for cracks.
•Check drive bevel pinion and drive bevel gear for wear or cracks.
•Check differential gears, pinions and pinion shafts for wear or damage.
•Check differential gear spline for wear or damage.
Sub-Assembly Adjustment and Reassembly
Judging from faulty conditions noted before disassembly and
what is found through visual check of bearing and gear tooth etc.
after disassembly, prepare replacing parts and proceed to reas-
sembly according to procedures as described below.
CAUTION:
Drive bevel gear and pinion must be replaced as a set
when either replacement becomes necessary.
When replacing taper roller bearing, replace as inner
race & outer race assembly.

7F-10 DIFFERENTIAL (REAR)
Differential carrier
For press-fitting drive bevel pinion bearing outer races, use spe-
cial tools as shown in the figure.
Special tool
(A) : 09924-74510
(B) : 09926-68310
(C) : 09913-75510
Differential case
1) After applying differential oil to differential gear (4), pinions
(5), pinion shafts (6), thrust washer (2) and spring washer
(1), install them in differential right case (3).
For correct installing direction of thrust washer (2) and spring
washer (1), refer to the figure.
2) When installing pinion shaft No.2 (2) (shorter) into differential
case and pinion, insert its “a” side into pinion joint (1).
3) Check differential pinion gear (1) for smooth rotation.
1. Differential carrier
NOTE:
“a” is longer than “b”. (“a” > “b”)
1
2
a
b
1

DIFFERENTIAL (REAR) 7F-11
4) In the same manner as described in Step 1), install thrust
washer (2), spring washer (1) and differential gear (4).
5) Install differential left case (1) and then tighten screws to
specified torque.
“A” : Cement 99000-32110
Tightening torque
Differential case screw (a) :
9 N·m (0.9 kg-m, 6.5 lb-ft)
6) Clean and degrease mating surface of drive bevel gear
(hypoid gear) (1).
7) Apply thread lock cement to hatched part of drive bevel gear
(1) as shown in the figure.
“A” : Cement 99000-32110
8) Put drive bevel gear (3) on differential case (1) and fasten
them with bolts (2) by tightening them to specified torque.
Use thread lock cement for bolts (2).
“A” : Cement 99000-32110
Tightening torque
Bevel gear bolts (a) : 105 N·m (10.5 kg-m, 76.0 lb-ft)
3. Differential left case
5. Differential pinion
3 Differential right case1
2, (a), “A”
32, (a), “A”
“
A”
1
CAUTION:
Use of any other bolts than that specified is prohibited.1
2, (a), “A”
3

7F-12 DIFFERENTIAL (REAR)
9) Install special tool to differential case assembly and check
that preload is within specification below. If preload exceeds
specified value, check if foreign matter is caught or gear is
damaged.
Special tool
(B) : 09928-06510
Side gear preload
: Max. 2.5 N·m (0.25 kg-m, 1.8 lb-ft)
Differential side bearing
1) Press-fit side bearing (1) with special tool and press.
Special tool
(A) : 09944-66020
2) Hold bearing press-fitted in Step 1) with holder and press-fit
side bearing on the other side.
Special tool
(A) : 09944-66020
(B) : 09951-16060
1. Torque wrench
2. Differential case assembly
3. Aluminum plate
4. Vise
(A)
1
NOTE:
Be sure to use bearing holder for the purpose of protect-
ing lower bearing.

DIFFERENTIAL (REAR) 7F-13
Drive bevel pinion
To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier
properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel
pinion, differential carrier and mounting dummy.
Special tool
(A) : 09900-20606
(B) : 09926-78320
(C) : 09922-75222
(D) : 09922-76570
(E) : 09951-46010
(F) : 09926-78311-002
1. Universal Joint flange (P/No. 27110-60A00)“a”: Pinion dummy height + Attachment height
2. Nut“b”: Axle dummy radius
3. Front bearing“a” + “b”Mounting dummy size 110.00 mm/4.3307 in.
4. Differential carrier“c”: Measured dimension
5. Rear bearing“d”: Drive bevel pinion mounting distance 110.00 mm/4.3307 in.
6. Spacer“e”: Shim size for mounting distance adjustment (= “c”)
7. Drive bevel pinion
8. Drive bevel gear

7F-14 DIFFERENTIAL (REAR)
1) Install special tools with bearings and universal joint flange
(2) to differential carrier (1).
Special tool
(E) : 09951-46010
(F) : 09926-78311-002
2) Tighten flange nut (1) so that specified bearing preload is
obtained.
Special tool
(C) : 09922-75222
(F) : 09926-78311-002
Pinion bearing preload
: 0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)
Spring measure reading with special tool
: 18N – 34N (1.8 – 3.4 kg, 4.0 – 7.5 lb) NOTE:
This installation requires no spacer or oil seal.
NOTE:
Before taking measurement with spring balance (2) or
torque wrench (3), check for rotation by hand and apply
small amount of differential oil to bearings.
On measuring preload, rotate the drive bevel pinion
about 1 rotation per 2 seconds.
4. Socket with adapter

DIFFERENTIAL (REAR) 7F-15
3) Set dial gauge to mounting dummy and make 0 (zero)
adjustment on surface plate.
Special tool
(A) : 09900-20606
(B): 09926-78320
4) Place zero-adjusted mounting dummy and dial gauge set on
pinion mounting dummy and take measurement between
zero position and extended dial gauge measuring tip.
Special tool
(A) : 09900-20606
(B) : 09926-78311
(D) : 09922-76570
(F) : 09926-78311-002
5) Obtain adjusting shim thickness by using measured value by
dial gauge in previous step. NOTE:
When setting dial gauge to mounting dummy, tighten
screw lightly. Be careful not to overtighten it, which will
cause damage to dial gauge.
With dial gauge set, turn dummy back and force by
hand a couple of times and attain accurate 0 (zero)
adjustment.
It is desirable that short pointer indicates beyond 2 mm
when long one is at 0 (zero).
1. Surface plate
2. Screw
NOTE:
Repeat turning back and force of dummy and measure
distance as far as top surface of pinion dummy accu-
rately.
When dial gauge measuring tip extends from 0 (zero)
position, pointer turns counterclockwise.
Measured value may exceed 1 mm. Therefore, it is also
necessary to know reading of short pointer.
Neces-
sary shim
thickness
“e”=Dial gauge
measured
value “c”