spring SUZUKI GRAND VITARA 2003 2.G Service Repair Manual

YH4
GRAND
VITARA
7B1-68 AUTOMATIC TRANSMISSION (4 A / T)
1. Select lever
2. Shift lock solenoid
3. Brake light switch
4. Brake pedal
5. Cable
6. Ignition switch
1. Select lever
2. Interlock cam3. Shift lock solenoid rod
4. Shift lock solenoid
Type-1
BRAKE INTERLOCK SYSTEM
SHIFT LOCK SOLENOID CONTROL
This system consists of shift lock solenoid control system and inter-
lock cable control system.
The shift lock solenoid control system is so designed that the selec-
tor lever can not be shifted from ªPº range position unless the igni-
tion switch is turned ON and the brake pedal is depressed. And the
interlock cable control system is so designed that the selector lever
cannot be shifted from ªPº range position unless the ignition switch
is turned to ªACCº or ªONº position. Also, the ignition key cannot be
pulled out of the key slot unless the selector lever is in ªPº range.
SHIFT LOCK SOLENOID CONTROL OPERATIONS
When the select lever is in ªPº range, the ignition key position is
ªONº and depressing the brake pedal cause the electric current to
flow to the solenoid. As the shift lock solenoid rod (or the lock plate)
is drawn toward the solenoid in this state, it frees the interlock cam
(or the detent pin), which then allows the select lever to be shifted
from ªPº range to any other position.
Even when the select lever is in ªPº range, if the ignition key position
is ªLOCKº or ªACCº or the brake pedal is not depressed, the electric
current does not flow to the solenoid.
In this state, the shift lock solenoid rod (or the lock plate) is pushed
away from the solenoid by spring force and it obstructs the interlock
cam (or the detent pin) movement. Thus the select lever button
does not work even when pressed and the select lever shift is pre-
vented.

YH4
GRAND
VITARA
1. Ignition switch assembly
2. Clamp screw
3. Outer end
1. Interlock cable
2. Steering column
3. Steering column
holder
Type-1
1. Interlock cam
2. Lever plate
3. Interlock cable
4. Pin with 4 mm (0.15 in.) dia.
7B1-72 AUTOMATIC TRANSMISSION (4 A / T)
Installation
1) Shift select lever to ªNº range and turn ignition key to ªACCº
position.
2) Connect inner end of interlock cable to key interlock lever (Igni-
tion switch side).
3) Install outer end bracket of interlock cable to ignition switch as-
sembly, and tighten screw to specified torque.
Tightening Torque
(a): 2.2 N
.m (0.22 kg-m, 1.5 lb-ft)
4) Pass and connect interlock cable as shown at the left figure.
TYPE-1
5) Fix interlock cam by inserting pin with about 4 mm (0.15 in.) dia.
into holes of cam and lever plate.
6) Install cable end to interlock cam and stud bolt and after making
sure that cable outer is pushed in arrow direction B by leaf
spring, tighten mounting nut to specified torque. Remove pin.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
7) Turn ignition key to ªACCº position and shift select lever to ªNº
range, and check for the followings.
a. When select lever is shifted at ªPº range with knob button
depressed, ignition key can not be turned from ªACCº to
ªLOCKº position.
b. When knob button is released, ignition key can be turned to
ªLOCKº position.
c. When ignition key is at ªLOCKº position, select lever can not
be shifted from ªPº to any other range.
8) Install console box.
9) Install steering column cover.
10) Adjust steering column or tighten steering column bolts.
11) Install steering column hole cover.
12) If equipped with air bag system, enable air bag system.
Refer to ªEnabling Air bag Systemº in Section 10B.

YH4
GRAND
VITARA
1. Inner end of interlock cable
2. Key release cam
1. Key release cam
2. Cable outer(a)
Type-2
Type-2
AUTOMATIC TRANSMISSION (4 A / T) 7B1-73
TYPE-2
5) With key release cam set as shown at the left figure, connect
inner end of interlock cable to key release cam. (Select lever
side.)
6) Move key release cam so that it is set at such angle as shown
at the left figure and with special tool inserted in hole A , fix key
release cam.
Special Tool
(A): 09925-78210 (6 mm)
7) With key release cam fixed with special tool, install cable outer
to bracket and after making sure that cable outer is pushed in
arrow direction B by leaf spring, tighten mounting nut to speci-
fied torque. Remove special tool.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
8) Turn ignition key to ªACCº position and shift select lever to ªNº
range, and check for the followings.
a. When select lever is shifted at ªPº range with knob button
depressed, ignition key can not be turned from ªACCº to
ªLOCKº position.
b. When knob button is released, ignition key can be turned to
ªLOCKº position.
c. When ignition key is at ªLOCKº position, select lever can not
be shifted from ªPº to any other range.
9) Install console box.
10) Install steering column cover.
11) Adjust steering column or tighten steering column bolts.
12) Install steering column hole cover.
13) If equipped with air bag system, enable air bag system.
Refer to ªEnabling Air bag Systemº in Section 10B.

YH4
GRAND
VITARA
1. Crankshaft
2. Flywheel
3. Clutch disc
4. Pressure plate
5. Clutch cover
6. Diaphragm spring
7. Release bearing
8. Input shaft bearing
9. Input shaft
10. Operating cylinder
11. Clutch housing
12. Release fork
7C1-2 CLUTCH
The clutch is a diaphragm-spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part,
with a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned
on the transmission input shaft with an involute spline
fit.
The clutch cover is secured to the flywheel, and car-
ries the diaphragm spring in such a way that the pe-
ripheral edge part of the spring pushes on the pres-
sure plate against the flywheel (with the disc in be-
tween), when the clutch release bearing is held back.
This is the engaged condition of the clutch.Depressing the clutch pedal causes the release bear-
ing to advance and pushes on the tips of the tapered
fingers of the diaphragm spring. When this happens,
the diaphragm spring pulls the pressure plate away
from the flywheel, thereby interrupting the flow of
drive from flywheel through clutch disc to transmis-
sion input shaft.
GENERAL DESCRIPTION

YH4
GRAND
VITARA
CLUTCH 7C1-3
DIAGNOSIS
ConditionPossible CauseCorrection
Slipping
Improper clutch pedal free travel.

Worn or oily clutch disc facing.

Warped disc, pressure plate or flywheel
surface.

Weakened diaphragm spring.

Master cylinder piston or seal cup not returning.Bleed air or replace master
cylinder.
Replace disc.
Replace disc, clutch cover or
flywheel.
Replace clutch cover.
Repair master cylinder.
Dragging clutch
Improper clutch pedal free travel.

Weakened diaphragm spring, or worn spring tip.

Rusted input shaft splines.

Damaged or worn splines of transmission
input shaft.

Excessively wobbly clutch disc.

Clutch facings broken or dirty with oil.

Fluid leakage.Bleed air or replace master
cylinder.
Replace clutch cover.
Lubricate.
Replace input shaft.
Replace disc.
Replace disc.
Repair or replace.
Clutch vibration
Glazed (glass-like) clutch facings.

Clutch facings dirty with oil.

Release bearing slides unsmoothly on input
shaft bearing retainer.

Wobbly clutch disc, or poor facing contact.

Weakened torsion springs in clutch disc.

Clutch disc rivets loose.

Distorted pressure plate or flywheel surface.

Weakened or loosened engine mounting
bolt or nut.Repair or replace disc.
Replace disc.
Lubricate or replace input
shaft bearing retainer.
Replace disc.
Replace disc.
Replace disc.
Replace clutch cover or flywheel.
Retighten or replace mounting.
Noisy clutch
Worn or broken release bearing.

Input shaft front bearing worn down.

Excessive rattle of clutch disc hub.

Cracked clutch disc.

Pressure plate and diaphragm spring rattling.Replace release bearing.
Replace input shaft bearing.
Replace disc.
Replace disc.
Replace clutch cover.
Grabbing clutch
Clutch disc facings soaked with oil.

Clutch disc facings excessively worn.

Rivet heads showing out of facing.

Weakened torsion springs.Replace disc.
Replace disc.
Replace disc.
Replace disc.

YH4
GRAND
VITARA
CLUTCH 7C1-11
INSPECTION
Input Shaft Bearing and Release Bearing
Check bearing for smooth rotation and replace it if abnormality is
found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance between rivet
head and facing surface. If depression is found to have reached
service limit at any of holes, replace disc assembly.
Rivet head depth
Standard: 1.6 mm (0.06 in.)
Service limit: 0.5 mm (0.02 in.)
Clutch Cover
1) Check diaphragm spring for abnormal wear or damage.
2) Inspect pressure plate for wear or heat spots.
3) If abnormality is found, replace it as assembly. Do not disas-
semble it into diaphragm and pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear or heat
spots. Replace or repair as required.

YH4
GRAND
VITARA
7D
TRANSFER 7D-1
The aluminum transfer case directly connected to the
back of the transmission contains the input gear,
countershaft & gear, output rear shaft, output low gear
and output front shaft (for front drive) connected by
way of the hyvo-chain.
The transfer has such a selective mechanism as to
enable the shift control lever to make selection of high
speed (direct connection with transmission output:
main shaft), low speed (speed reduction by input
gear, counter gear and output low gear) or neutral by
way of the reduction sleeve located between input
gear and output low gear, and selection of two-wheel-
drive (high speed only) or four-wheel-drive (high or
low speed) by way of the front drive clutch sleeve lo-cated at the center of the output rear shaft. Also, with
a synchronizer installed to the front drive clutch, it is
possible to change the drive mode between 2WD
(high speed only) and 4WD (high speed only) even
while running.
The front drive shift fork has an auxiliary spring to
make a smooth shift from 4H to 2H possible.
The case has an oil gutter and a plate at synchronizer
to provide proper lubrication even under the strict
conditions of use.
WARNING:
For towing the vehicle for the purpose of repair or
the like, follow the towing instructions in OWN-
ER'S MANUAL.
SECTION 7D
TRANSFER
CONTENTS
GENERAL DESCRIPTION7D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Oil7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Oil Seals7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Driven Gear7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Assembly7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remounting7D-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION

YH4
GRAND
VITARA
7D-2 TRANSFER
DIAGNOSIS
DIAGNOSIS TABLE
Before attempting to repair the transfer or related components for any reason other than mechanical failure, the
condition and probable causes should be identified.
Transfer failures are revealed by shifting difficulties such as excessive shifting effort, gear clash, or gear grinding.
When any of these conditions occur, the following inspections should be made before disassembling the transfer.
1) Check transfer oil level for insufficient or incorrect oil. Refer to ªTransfer and Differential Oil Inspection and
Changeº in SECTION 0B ªMAINTENANCE AND LUBRICATIONº.
2) Check transfer mountings for wear or looseness.
3) Check gearshift control lever for distortion or excessive wear.
After performing the above inspections, refer to following diagnosis table.
Condition
Possible CauseCorrection
Gear slipping out of mesh
Worn shift fork shaft

Worn shift fork or synchronizer sleeve

Weak or damaged locating spring

Worn bearings on output rear shaft

Worn chamfered tooth on sleeve or gear

Missing or disengagement of circlip(s)Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengage
Weakened or broken synchronizer spring

Distorted shift shaft or shift forkReplace
Replace
Hard shifting
Weakened front drive shift shaft spring

Distorted or mispositioned front drive shift
shaft circlip and washer

Inadequate or insufficient lubricant

Worn synchronizer ring

Worn chamfered tooth on sleeve or gear

Distorted shift shaftReplace
Replace
Replenish
Replace
Replace sleeve and gear
Replace
Noise
Inadequate or insufficient lubricant

Damaged or worn bearing(s)

Damaged or worn gear(s)

Damaged or worn synchronizer ring

Damaged or worn chamfered tooth on
sleeve or gearReplenish
Replace
Replace
Replace
Replace

YH4
GRAND
VITARA
7E-4 DIFFERENTIAL (FRONT)
Components and Functions
ComponentFunction
4WD switch
When the transfer shift lever is shifted to 4L or 4H position, this switch turns ON
and causes the 4WD control system to turn ON, unless it is shifted to N or 2H
within 1 second.
ECM or PCM
When the 4WD switch turns ON [unless it turns OFF within 1 second], this com-
ponent actuates the pump assembly. If the pressure in the air pump assembly
fails to increase higher than the set level even after the pump motor has run more
than 10 seconds, this component stops the motor to protect it.
Air pump assembly

Pump motor

Release valve

Pressure switchThe air pump assembly consists of a pump motor, release valve and a pressure
switch.
Pump motor:
Produces positive pressure which actuates the actuator.
Release valve:
Closes when transfer shift lever is shifted to 4H or 4L so that the positive pressure
is applied to the actuator, and opens when N or 2H to release the pressure to the
atmosphere.
Pressure switch:
Turns ON and OFF depending on the pressure level in the pump assembly
(whether higher or lower than the set pressure level). ECM or PCM detects the
pressure level through this switch.
Differential case assembly

Free axle hub

Axle lock clutch

ActuatorThe free axle hub, axle lock clutch and actuator are installed in the differential
left case. The positive pressure produced in the air pump assembly is applied
to the actuator which then pushes the axle lock clutch to be engaged with the free
axle hub. In this state, the drive force is transmitted to the front axle, resulting in
the 4WD mode.
When the actuator is free from the positive pressure [when it is under the atmo-
spheric pressure], the axle lock clutch is pushed back by the return spring force
and cannot be engaged with the free axle hub, resulting in the 2WD mode.
ª4WDº indicator lampIt lights up when 4WD control system is in the 4WD mode.