rear axle removal SUZUKI GRAND VITARA 1999 2.G Service Workshop Manual

YH4
GRAND
VITARA
1. Rear axle housing
2. Floor jack
1. Lock nut (if equipped)
2. Absorber nut
3. Upper support
4. Rubber bush
5. Lower support
6. Shock absorber
7. Bolt
Upper side
Lower side
1. Lock nut (if equipped)
2. Absorber nut
3. Body outside
REAR SUSPENSION 3E-5
ON-VEHICLE SERVICE
SHOCK ABSORBER
The shock absorber is non-adjustable, non-refillable, and cannot
be disassembled. The only service the shock absorber requires is
replacement when it has lost its resistance, is damaged, or leaking
fluid.
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack to prevent it from
lowering.
3) Remove lock nut (if equipped) and absorber nut.
4) Remove lower mounting bolt.
5) Remove shock absorber.
INSTALLATION
1) Install shock absorber. Refer to figure for proper installing direc-
tion of lower mounting bolt.
2) Remove floor jack.
3) Lower hoist.
4) Tighten nuts to specified torque.
NOTE:

Tighten lower nut with vehicle off hoist and in non-loaded
condition.
Tightening Torque
(a): 29 N
.m (2.9 kg-m, 21.0 lb-ft)
(b): 85 N
.m (8.5 kg-m. 61.5 lb-ft)

YH4
GRAND
VITARA
1. Parking brake
cable hanger
2. Cross member
3. Clamp
4. Chassis frame1. Rear axle housing
2. Floor jack
1. Shock absorber
2. Lower bolt
1. Clamp
2. Upper rod
3E-6 REAR SUSPENSION
COIL SPRING
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack.
3) Disconnect parking brake cable hanger from chassis frame and
clamp from cross member.
4) Remove shock absorber lower mounting bolt.
5) Remove wheel speed sensor clamps from upper rod and axle
housing, if equipped with ABS.
For right side, remove E-ring for fixing brake pipe from cross
member and disconnect breather hose from axle housing.
6) Lower rear axle housing gradually as far down as where coil
spring can be removed.
7) Remove coil spring.

YH4
GRAND
VITARA
1. Axle housing
2. Floor jack
1. Lower rod
2. Rear mount nut1. Lower rod
2. Front mount bolt
1. Lower rod
2. Front bolt
3. Rear bolt
4. Vehicle body
5. Axle housing
6. Body center
7. Body out side
[A]: Body side
[B]: Axle side
3E-8 REAR SUSPENSION
LOWER ROD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack.
3) Remove lower rod front mount bolt.
4) Remove lower rod rear mount bolt.
INSTALLATION
1) Install lower rod to chassis frame and axle housing, referring to
figure for proper installing direction of bolts.
Nuts should not be tightened.
2) Remove floor jack from rear axle housing.
3) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque for wheel nuts
100 N
.m (10.0 kg-m, 72.5 lb-ft)
4) Lower hoist and with vehicle in non loaded condition, tighten
front bolt and rear nut of lower rod to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65.0 lb-ft)

YH4
GRAND
VITARA
1. Clamp
2. Upper rod
1. Upper rod front bolt
2. Nut
3. Upper rod
4. Wheel speed sensor
harness bracket
(Toward outside of body)1. Upper rod
2. Bolt
5. Upper rod rear bolt
6. Washer
7. Body center
8. Front side
REAR SUSPENSION 3E-9
UPPER ROD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) If equipped with ABS, disconnect wheel speed sensor harness
clamp from left upper rod.
3) Remove upper rod.
INSTALLATION
1) Install upper rod to chassis frame and axle housing, referring to
figure for installing direction of bolts.
Nuts should not be tightened.
2) See figure for distinction of installing direction of left side upper
rod for vehicle equipped with ABS.
3) Connect wheel speed sensor harness clamp to upper rod (if
equipped with ABS).
4) Lower hoist and with vehicle in non-loaded condition, tighten
front bolt and rear nut of upper rod to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65 lb-ft)

YH4
GRAND
VITARA
(a)
(a)
1. Bolt
2. Washer
3. Lateral rod
1. Nut
1
3E-10 REAR SUSPENSION
LATERAL ROD
REMOVAL
1) Hoist vehicle.
2) Remove lateral rod mounting bolts.
3) Remove lateral rod.
INSTALLATION
1) Install lateral rod to rear axle, and vehicle body.
2) Lower hoist.
3) Tighten lateral rod mounting bolts to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65.0 lb-ft)
REAR AXLE SHAFT AND WHEEL BEARING
REMOVAL
1) Remove rear brake drum. For details, refer to REAR BRAKE
DRUM REMOVAL in SECTION 5C.
2) Drain gear oil from rear axle housing by loosening drain plug.
3) Remove rear wheel bearing retainer nuts from axle housing.

YH4
GRAND
VITARA
[B]
1
2
[A]
1. Bearing retainer
2. Oil seal
3. Wheel side
4. Differential side
1. Stud bolt
2. Nut
3. Washer
4. Flange of axle shaft
1. Axle shaft
2. Bearing retainer
[A]: Vehicle without ABS
[B]: Vehicle with ABS
1. Bearing
2. Retainer ring
REAR SUSPENSION 3E-13
INSTALLATION
Install removed parts in reverse order of removal procedure, noting
the following.
1) Apply grease to oil seal lip as shown and install it to axle shaft.
NOTE:
Amount of grease applied to hollow in oil seal should be
more than 60% of its vacant space.
ªAº: Grease 99000-25010
2) Aligning serrations between new stud bolt(s) and flange, install
new stud bolt(s) by tightening nut as shown.
3) Install bearing retainer to shaft.
4) Press-fit wheel bearing and retainer ring as shown.
NOTE:

Use care not to cause any damage to outside of retainer
ring.

Refer to figure so that wheel bearing is installed in proper
direction.

YH4
GRAND
VITARA
REAR SUSPENSION 3E-15
1. Inner oil seal
2. Axle housing
1. Hammer
2. Screwdriver
3. Oil seal protector
4. Oil seal
5. Body center
REAR AXLE SHAFT INNER OIL SEAL
REMOVAL
1) Remove rear axle shaft. For details, refer to steps 1) to 7) of
REAR AXLE SHAFT REMOVAL in this section.
2) Fix brake back plate by inserting screwdriver to the hole for bear-
ing retainer mounting.
3) Remove rear axle shaft inner oil seal.
NOTE:
Take care not to bend the brake pipe.
INSTALLATION
1) Using special tool drive in oil seal until it contacts oil seal protec-
tor in axle housing.
NOTE:

Make sure that oil seal is free from inclination as it is
installed.

Refer to figure so that oil seal is installed in proper direc-
tion.
Special Tool
(A): 09913-75510
ªAº: Grease 99000-25010
ªBº: Sealant 99000-31110
2) For procedure hereafter, refer to steps 6) to 11) of REAR AXLE
SHAFT INSTALLATION in this section.

YH4
GRAND
VITARA
1. Brake pipe flare nut
2. Brake pipe
3. Brake back plate
1. Bearing retainer
2. Parking brake shoe
lever
3. Clearance1. Nut 1. Wheel speed sensor
2. Wheel speed sensor coupler
3. Wheel speed sensor harness clamp
4. Wheel speed sensor harness
3E-16 REAR SUSPENSION
REAR AXLE HOUSING
REMOVAL
1) Drain differential gear oil.
Carry out steps 2) to 7) and 15) to 18) on both right and left
wheels.
Note that left wheel and its related parts are used in illustrations
in this section.
2) Remove rear brake drum. (Refer to steps 1) to 5) of BRAKE
DRUM REMOVAL.)
3) Disconnect brake pipe from wheel cylinder. With right side wheel
cylinder, disconnect 2 brake pipes.
4) For vehicle with ABS, disconnect wheel speed sensor coupler
and remove wheel speed sensor with its harness.
5) Remove rear wheel bearing retainer nuts from rear axle hous-
ing.
6) Check to ensure that there is clearance between rear wheel
bearing retainer and parking brake shoe lever. If no clearance
is found, loosen cable locking nut further to obtain clearance.

YH4
GRAND
VITARA
1. Lower rod
2. Body center
1. Rear axle housing
2. Spring seat
3. Coil spring
4. Stepped part
1. Axle housing ªAº 1. Body center
1
2
1
REAR SUSPENSION 3E-19
INSTALLATION
Install removed parts in reverse order of removal, noting the follow-
ing.
1) Place rear axle housing on floor jack. Then install upper / lower
rod rear mounting bolts (right & left) in proper direction as shown
(refer to UPPER ROD INSTALLATION for upper rod bolts). At
this time, mount nuts but don't tighten them.
2) Install coil spring (right & left) on spring seat of axle housing and
raise axle housing.
NOTE:
When seating coil spring, mate spring end with stepped
part of rear axle spring seat as shown.
3) Install lateral rod to rear axle housing.
4) Install lower part of shock absorber to right and left sides of axle
housing and install bolts in proper direction as shown in figure.
At this time, mount nuts but don't tighten them.
5) Clean mating surfaces of axle housing and differential carrier
and apply sealant to housing side.
ªAº: Sealant 99000-31110
6) Install differential carrier assembly to axle housing and tighten
carrier nuts to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7
1. Rear axle
2. Shock absorber
3. Clamp
1. Brake pipe (to rear)
2. Brake pipe
(to LSPV, for vehicle without ABS)
3. 4-way (2-way) joint
4. Chassis frame
REAR BRAKE HOSE / PIPE
REMOVAL
1) Raise and suitably support vehicle. Remove tire and wheel.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.
INSTALLATION
1) Reverse removal procedure for brake hose or pipe installation procedure.

Be sure to obtain more than 3 mm (0.118 in.) clearance between axle housing and brake pipe.

Install clamps properly referring to figure below and tighten bolts.

When installing hose, make sure that it has no twist or kink.
2) Fill and maintain brake fluid level in reservoir. Bleed brake system.
3) Perform brake test and check each installed part for fluid leakage.