Axle oil SUZUKI GRAND VITARA 2004 2.G Service User Guide

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
1. Sensor rotor
1. Axle housing
1. Bearing retainer
(b)
3E-14 REAR SUSPENSION
5) For vehicle with ABS, press-fit new sensor rotor as shown.
NOTE:
Use care not to cause any damage to outside of retainer
ring.
6) Apply grease to axle shaft inner oil seal lip as shown.
ªAº: Grease 99000-25010
7) Apply sealant to mating surface of bearing retainer with brake
back plate.
NOTE:
Make sure to remove old sealant before applying it anew.
ªBº: Sealant 99000-31110
8) Install rear axle shaft to rear axle housing and tighten bearing
retainer nuts to specified torque.
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
9) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening Torque
(b): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
10) Refill rear axle (differential) housing with new specified gear oil.
Refer to SECTION 7F for refill.
11) Install brake drum. (For details, refer to BRAKE DRUM
INSTALLATION in SECTION 5.)

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
3E-18 REAR SUSPENSION
1. Axle housing
2. Jack
1. Differential carrier
assembly
2. Differential carrier nut
1. Lower rod
2. Lower rod rear
mount nut
3. Shock absorber
1. Lower mount
bolt
13) For jobs hereafter, support rear axle housing by using floor jack
under axle housing.
14) Remove differential carrier assembly.
15) Loosen rear mount nut of upper rod but don't remove bolt.
16) Loosen rear mount nut of lower rod but don't remove bolt.
17) Remove rear axle side lateral rod mount bolt.
18) Remove shock absorber lower mount bolt.
19) Lower floor jack until tension of suspension coil spring be-
comes a little loose and remove rear mount bolt of upper , lower
and lateral rod.
20) Lower rear axle housing gradually.
21) Remove axle housing.

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
1. Axle housingªAº
(c)
1. Axle housing
3E-20 REAR SUSPENSION
7) For vehicle with ABS, connect wheel speed sensor coupler and
install harness.
8) Install propeller shaft and torque nuts to specification.
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
9) Remove floor jack from axle housing and connect breather
hose onto axle housing and clamp it securely.
10) Connect brake pipes onto axle housing and clamp them se-
curely.
For clamping positions, refer to SECTION 5A of this manual.
11) Connect brake flexible hose to bracket on axle housing and se-
cure it with E-ring.
12) Install LSPV stay to axle housing, tighten LSPV stay bolt to
specified torque.
And adjust LSPV referring to ªLSPV ASSEMBLY INSPEC-
TION AND ADJUSTMENTº in SECTION 5A.
Tightening Torque
(c): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
13) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening Torque
(d): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
14) Clean mating surface of axle housing (right & left) and brake
back plate, then apply sealant as shown.
ªAº: Sealant 99000-31110
15) Apply grease to axle shaft inner oil seal lip as shown.
ªAº: Grease 99000-25010

YH4
GRAND
VITARA
3. Container 1. Plug cap
2. Vinyl tube
1. Bearing retainer
(e)
(f)
(g)
REAR SUSPENSION 3E-21
16) Apply sealant to mating surface of bearing retainer with brake
back plate.
NOTE:
Make sure to remove old sealant before applying it anew.
ªBº: Sealant 99000-31110
17) Install rear axle shaft to rear axle housing and tighten bearing
retainer nuts to specified torque.
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
Tightening Torque
(e): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
18) For vehicle with ABS, tighten wheel speed sensor bolt to speci-
fied torque.
Tightening Torque
(f): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
19) Connect brake pipes to wheel cylinders (right & left) and tighten
brake pipe flare nuts to specified torque.
Tightening Torque
(g): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
20) Install brake drum (right & left). For details, refer to SECTION
5C ªBRAKE DRUM INSTALLATIONº.
21) Refill differential gear housing with new specified gear oil. Re-
fer to ªON-VEHICLE SERVICEº in SECTION 7F for refill.
22) Fill reservoir with brake fluid and bleed brake system.(For
bleeding operation, see SECTION 5.)

YH4
GRAND
VITARA
REAR SUSPENSION 3E-23
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mKg-mlb-ft
Shock absorber lock nut292.921.0
Shock absorber nut292.921.0
Shock absorber lower nut858.561.5
Lower rod bolt and nut
Upper rod bolt and nut909.065.0
Lateral rod bolt
Differential carrier nut555.540.0
Propeller shaft nut505.036.5
Brake pipe flare nut161.611.5
Bearing retainer nut232.317.0
Differentiation gear oilFiller plug505.036.5g
filler & drain plugDrain plug272.716.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
Brake fluidDOT 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 oilFor gear oil information, refer to
SECTION 7F of this manualDifferential gear
(Refer axle housing.)