axle SUZUKI GRAND VITARA 1999 2.G Owners Manual

REAR SUSPENSION 3E-1
3E
SECTION 3E
REAR SUSPENSION
CONTENTS
On-Vehicle Service......................................... 3E-1
Rear Axle Shaft and Wheel Bearing ............ 3E-1
Rear Axle Shaft Inner Oil Seal ..................... 3E-5
Rear Axle Housing ....................................... 3E-5Tightening Torque Specification .................. 3E-6
Required Service Material ............................. 3E-6
Special Tool .................................................... 3E-7

On-Vehicle Service
Rear Axle Shaft and Wheel Bearing
REMOVAL
1) Remove axle shaft from axle housing according to Step1) to
6) in the same section in the service manual mentioned in
the FOREWORD of this manual noting following points. NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in the FOREWORD of this manual.
All suspension fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or
damage to the part may result.

3E-2 REAR SUSPENSION
2) Remove circlip from axle shaft.
3) In order to remove retainer ring (1) from axle shaft (3), grind
with a grinder two portion (2) of bearing retainer ring as illus-
trated till it becomes thin.
4) Break with a chisel (1) the thin ground sensor rotor and
retainer ring, and it can be removed.
5) Remove wheel bearing (1) and bearing retainer (2) using
special tools as shown in figure.
Special tool
(A) : 09927-18411
(B) : 09921-57810 CAUTION:
Be careful not to grind axle shaft.
[A]: Vehicle with ABS
[B]: Vehicle without ABS
NOTE:
If inner race of wheel bearing is left in axle shaft, remove
it from axle shaft with the same procedure as above-
mentioned.
CAUTION:
Do not reuse wheel bearing.

REAR SUSPENSION 3E-3
6) Remove stud bolt(s) (1) by using hydraulic press (2).
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
1) Aligning serrations between new stud bolt(s) (1) and flange
(4), install new stud bolt(s) (1) by tightening nut (2) as shown
in the figure.
2) Install bearing retainer (2) to axle shaft (1).
3) Press fit new wheel bearing (1) and new retainer ring (2)
using press (3).
4) Install circlip to axle shaft.
3. Washer
NOTE:
Use care not to cause any damage to outside of
retainer ring (2).
Seal side (4) of wheel bearing must face bearing
retainer (5) side.

3E-4 REAR SUSPENSION
5) Apply grease “A” to axle shaft inner oil seal lip as shown in
the figure.
“A” : Grease 99000-25010
6) Apply water tight sealant “B” to mating surfaces of brake
back plate and rear axle hub (2).
“B” : Water tight sealant 99000-31110
7) Install rear axle shaft to rear axle housing and tighten bear-
ing retainer nuts to specified torque.
Rear axle shaft length “L”
Left side : 700.5 mm (27.6 in.)
Right side : 769.5 mm (30.3 in.)
Tightening torque
Bearing retainer nut (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
8) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening torque
Wheel speed sensor bolt (b) : 21 N·m (2.1 kg-m, 15.5 lb-ft)
9) Refill rear axle housing with new specified gear oil.
Refer to “MAINTENANCE SERVICE” in Section 7F.
10) Install brake drum. Refer to “BRAKE DRUM” in Section 5C.
1. Axle housing
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
(b)

REAR SUSPENSION 3E-5
Rear Axle Shaft Inner Oil Seal
INSTALLATION
1) Using special tool drive in oil seal until it contacts oil seal pro-
tector in axle housing.
Special tool
(A) : 09924-74510
(B) : 09944-88210
“A” : Grease 99000-25010
“B” : Sealant 99000-31110
2) For procedure hereafter, refer to steps 6) to 11) of “INSTAL-
LATION” under “REAR AXLE SHAFT” in the service manual
mentioned in the FOREWORD of this manual.
Rear Axle Housing
INSTALLATION
For Step 1) to 4), 7) and 9) to 30), refer to the same section in the
Service Manual mentioned in the FOREWORD of this manual.
3) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant “A” to housing side.
“A” : Sealant 99000-31110
4) Install differential carrier assembly to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Differential carrier bolt (a) :
55 N·m (5.5 kg-m, 40.0 lb-ft) NOTE:
Make sure that oil seal is free from inclination as it is
installed.
Refer to the figure so that oil seal is installed in proper
direction.
1. Hammer 4. Oil seal
2. Rod 5. Body center
3. Oil seal protector

3E-6 REAR SUSPENSION
5) Apply thread lock cement to thread of propeller shaft flange
bolt if reused. Install propeller shaft to joint flange aligning
match marks and torque flange nuts to specification.
“A” : Cement 99000-32110
Tightening torque
Propeller shaft nut (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
Tightening Torque Specification
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Shock absorber nut 29 2.9 21.0
Shock absorber lower nut 85 8.5 61.5
Lower rod bolt and nut 100 10.0 72.5
Upper rod bolt and nut 100 10.0 72.5
Lateral rod bolt 100 10.0 72.5
Differential carrier bolt 55 5.5 40.0
Propeller shaft nut 60 6.0 43.5
Brake pipe flare nut 16 1.6 11.5
Bearing retainer nut 50 5.0 36.5
Differentiation gear oil filler & drain plug (filler plug) 50 5.0 36.5
Differentiation gear oil filler & drain plug (drain plug) 27 2.7 16.0
Wheel nut 100 10.0 72.5
Wheel speed sensor bolt 21 2.1 15.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
Brake fluid DOT 3Brake reservoir tank
Sealant SUZUKI BOND NO. 1215
(99000-31110)Joint seam of axle and brake back plate
Joint seam of bearing retainer and brake
back plate
Joint seam of differential carrier and axle
housing
Drain plug
Mating surface of oil seal and axle housing
Gear oil For gear oil information, refer to Section 7FDifferential gear (Rear axle housing)
Thread lock
cementTHREAD LOCK CEMENT SUPER 1322
(99000-32110)Rear propeller shaft flange bolts

4A2-4 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL
Required Service Material
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Drive shaft oil seal
Wheel spindle part of differential
side drive shaft (RH)
Sealant SEALING COMPOUND 366E
(99000-31090)Axle shaft drive flange

PARKING AND REAR BRAKE 5C-3
On-Vehicle Service
Parking Brake CableBrake Drum
INSPECTION
Brake drum
Inspect drum for cleanliness. Check wear of its braking surface by
measuring its inside diameter.
Whenever brake drums are removed, they should be thoroughly
cleaned and inspected for cracks, scores, deep grooves.Brake dram inside diameter “a ”
S ta n dard : 2 54 mm (9.99 in .)
S erv ic e L im it : 2 56 m m ( 10.07 i n.)
1. Parking brake switch 6. Equalizer 11. Color ring 16. Crossmember 21. Parking brake cable nut
2. Parking brake lever 7. Pin 12. Cable 17. Chassis frame Tightening torque
3. Parking brake lever bolt 8. Equalizer 13. Grommet 18. Hanger
4. Floor 9. Adjust rod 14. Bolt 19. Rear axle
5. Locking nut 10. Coupler 15. Clamp (if equipped) 20. G-sensor (if equipped)

PARKING AND REAR BRAKE 5C-5
Wheel Cylinder
INSTALLATION
For the details, refer to the same item of the same section in the
service manual mentioned in the FOREWORD of this manual not-
ing the following points.
Take off bleeder plug cap from brake pipe and connect pipe
(or pipes) to wheel cylinder (1) just enough to prevent fluid
from leaking.
Tighten wheel cylinder to brake back plate (1) to specified
torque.
Tightening torque
Wheel cylinder bolt (for non sealed type) (a):
13.5 N·m (1.35 kg-m, 10.0 lb-ft)
Brake pipe flare nut (b):
16 N·m (1.6 kg-m, 12.0 lb-ft)
Brake Back Plate
INSTALLATION
1) Install brake back plate (3) to rear axle shaft (1).
2) Apply sealant “A” to joint seam of rear axle housing (1) and
brake back plate.
“A” : Sealant 99000-31110
3) Install rear axle shaft to rear axle housing.
2. Wheel beaning
NOTE:
Make sure to remove old sealant before applying it anew.

ANTILOCK BRAKE SYSTEM (ABS) 5E2-33
Rear Sensor Rotor (Retainer Ring)
REMOVAL
1) Remove rear axle shaft assembly. Refer to “REAR AXLE
SHAFT” in Section 3E.
2) In order to remove sensor rotor (retainer ring) (2) from shaft
(1), grind with a grinder one part “A” of the sensor rotor
(retainer ring) as shown till it becomes thin.
3) Break with a chisel (1) the thin ground sensor rotor (retainer
ring) (2), and it can be removed.
INSTALLATION
1) Press-fit sensor rotor (retainer ring) (1) as shown in the fig-
ure.
2) Install rear axle shaft assembly. Refer to “REAR AXLE
SHAFT” in Section 3E. CAUTION:
Cover vinyl sheet (3) or the like over wheel bearing so
that fine grains from grinding will not enter there.
Be careful not to go so far as to grind the retainer ring.