boot SUZUKI GRAND VITARA 2004 2.G Service User Guide

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.
STABILIZER BAR AND BUSHING CHECK
BAR
Inspect for damage or deformation. If defective, replace.
BUSHING
Inspect for damage, wear or deterioration. If defective, replace.
STRUT DAMPER AND / OR COIL SPRING
CHECK
1) Inspect strut for oil leakage. If strut is found faulty, replace it as
an assembly unit, because it can not be disassembled.
2) Strut function check
Check and adjust tire pressures as specified.
Bounce body three or four times continuously by pushing front
end on the side with strut to be checked. Apply the same amount
of force at each push and note strut resistance both when
pushed and rebounding.
Also, note how many times vehicle body rebounds before com-
ing to stop after hands are off. Do the same for strut on the other
side.
Compare strut resistance and number of rebound on the right
with those on the left.
And they must be equal in both. With proper strut, body should
come to stop the moment hands are off or after only one or two
small rebounds. If struts are suspected, compare them with
known good vehicle or strut.
3) Inspect for damage or deformation.
4) Inspect strut boot for damage or crack.
5) Inspect for cracks or deformation in spring seat.
6) Inspect for deterioration of bump stopper.
7) Inspect strut mount for wear, cracks or deformation.
Replace any parts found defective in steps 2) ± 7).
SUSPENSION ARM / KNUCKLE CHECK
Inspect for cracks, deformation or damage.

YH4
GRAND
VITARA
4A2
1. Drive shaft oil seal
2. Double off set joint (DOJ)
3. Joint circlip
4. DOJ boot
5. Ball joint boot
6. Ball joint assembly (RH side)
7. Drive shaft assembly (LH side)
8. Left drive shaft
9. Drive shaft bearing circlip
10. Drive shaft bearing
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-1
SECTION 4A2
FRONT DRIVE SHAFT/SHAFT BEARING,
OIL SEAL
CONTENTS
GENERAL DESCRIPTION4A2- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS4A2- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table4A2- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Boot And Joint Check 4A2- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE4A2- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft4A2- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Bearing / Oil Seal4A2- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
The drive shaft joint is a constant velocity joint (C.V. joint) which slides in the axial direction. The joint is composed
of an outer race, cage, inner race and balls. In the turning direction, the joint rotates in the same way as a ball bear-
ing. The balls lock rotation completely and transmit drive. In addition this vehicle is also characterized by a function
that the shaft can slide through the balls in the grooves of the outer race in the extension / contraction direction of
the drive shaft.

YH4
GRAND
VITARA
4A2-2 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
DIAGNOSIS
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
When starting:
Abnormal Noise
Loose wheel nuts.

Loose drive shaft flange bolts.

Broken or otherwise damaged wheel
bearing.Tighten wheel nuts.
Tighten drive shaft flange bolts.
Replace or change.
When making turns:
Abnormal Noise
Grease leakage from drive shaft joint
boot.

Worn or broken drive shaft joint.Replace joint boot and apply grease.
Replace drive shaft joint.
When running:
Abnormal Noise
Broken drive shaft joint.

Poorly lubricated or worn drive
shaft joint.

Loose drive shaft flange bolts.

Deformed drive shaft oil seal.Replace drive shaft joint.
Lubricate or replace joint.
Tighten drive shaft flange bolts.
Replace.
Vibration
Worn drive shaft joint.

Deformed drive shaft oil seal.

Deformed drive shaft.Replace drive shaft joint.
Replace.
Replace.
DRIVE SHAFT BOOT AND JOINT CHECK
Check drive shaft boot for tear. If even a small tear is noted, replace
with new one.
Check drive shaft joint for wear, breakage and other damage and
replace if any defect exists.

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Drive shaft flange
bolts and nuts
1. Oil seal
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3
ON-VEHICLE SERVICE
DRIVE SHAFT
REMOVAL (LEFT SIDE)
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange.
3) Remove drive shaft circlip and front spindle thrust washer.
4) Remove drive shaft flange bolts and nuts.
5) Remove drive shaft assembly to differential side as shown in left
figure.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
6) Remove drive shaft thrust washer (vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Differential side joint
2. Tire lever
3. Front differential assembly
1. Oil seal 2
1
4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
REMOVAL (RIGHT SIDE)
1) Hoist vehicle and remove wheel.
2) Drain differential gear oil.
3) Remove axle shaft drive flange.
4) Remove circlip and front spindle thrust washer.
5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and
9) to 14) of item COIL SPRING REMOVAL in Section 3D.
6) Remove drive shaft assembly.
To detach snap ring fitted on the spline of differential side joint
(inboard joint) from differential side gear, pull inboard joint by us-
ing a tire lever.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
7) Remove drive shaft thrust washer (to vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
1. Boot
2. Snap ring
1. Circlip
2 Snap ring plier
3. Cage
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5
DISASSEMBLY
1) Remove boot band of differential side joint.
2) Slide boot toward the center of shaft and remove snap ring from
outer race, then take shaft out of outer race.
3) Remove circlip and then cage.
4) Remove inside and outside boots from shaft.
CAUTION:

Do not disassemble wheel side joint (outboard joint). If
any malcondition is found in joint, replace it as assem-
bly.

Do not disassemble ball joint of differential side joint.
If any malcondition is found in ball joint, replace differ-
ential side joint assembly.
INSPECTION

Check boots for breakage or deterioration. Replace them as nec-
essary.

Check circlip, snap ring and boot bands for breakage or deforma-
tion. Replace as necessary.
CLEANING

Wash disassembled parts (except boots) in degreaser. After
washing, dry parts completely by blowing air.

Clean boots with cloth. DO NOT wash boots in degreaser, such
as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.

YH4
GRAND
VITARA
1. Boot
2. Boot band
1. Circlip1. Cage Wheel side
ªAº Fill grease 85g (3.0 oz)
4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
ASSEMBLY
CAUTION:

To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with cloth
is allowed.

For M / T vehicle with H25 engine
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. i.e. yellow
grease to wheel side joint and black one to differential
side.

Bend each boot band against forward rotation.

Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its du-
rability.
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 90 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.
5) Install cage to shaft.
CAUTION:
Install cage directing smaller outside diameter side to
shaft end.
6) Install circlip by using snap ring plier.

YH4
GRAND
VITARA
ªAº: Fill grease 90 ± 95 g (3.2 ± 3.4 oz)
1. Circlip
[LH] [RH] Differential side
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7
7) Apply grease to entire surface of cage.
Use joint grease in tube included in spare part or joint grease
(99000-25120).
8) Insert cage into outer race and fit circlip into groove of outer
race.
CAUTION:
Position opening of circlip ªaº so that it will not be lined
up with a ball.
9) Apply grease to inside of outer race, and fit boot to outer race.
Fill up inside of boot with joint grease.
ªAº: Joint Grease 99000-25120
(about 90 ± 95g / 3.2 ± 3.4 oz)
10) Fitting boot to outer race, adjust so that measurements ªbº and
ªcº become as indicated in figure.
Length ªbº: 203.2 ± 213.2 mm
(8.00 ± 8.40 in.)
196.8 ± 206.8 mm
(7.75 ± 8.14 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
ªcº: 125.5 ± 135.5 mm
(4.94 ± 5.33 in.)
127.5 ± 137.5 mm
(5.02 ± 5.41 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
Before fixing boot band, insert screwdriver into boot on joint
side and allow air to enter boot so that air pressure in boot be-
comes the same as atmospheric pressure.
11) Clamp boot band. Check boots for distortion or dent.

YH4
GRAND
VITARA
1. Drive shaft oil seal
1. Drive shaft flange bolt and nut
2. Front spindle thrust washer
3. Axle shaft drive flange
ªAº
1. Drive shaft joint
2. Oil seal
3. Pipe
4. Thrust washer4
4A2-8 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
INSTALLATION
Install drive shaft assembly by reversing removal procedure and
noting following points.

Clean front drive shaft oil seal and then apply lithium grease to oil
seal and DOJ shaft.
ªAº: Grease 99000-25010

Check oil seal for breakage or deterioration.
Replace it as necessary.

Drive in oil seal until its end contacts stepped surface of drive
shaft joint by using a pipe whose inner diameter is 76 mm (2.992
in.) or more and outer diameter is 80 mm (3.150 in.) or less.
Diameter ªaº: 76 mm (2.992 in.) or more
Diameter ªbº: 80 mm (3.150 in.) or less

Drive in drive shaft thrust washer (Vehicle with G16 or J20 en-
gine).

RH Side
Push differential side joint by hand until it is positioned by snap
ring fitted to its spline.
LH Side
Connect drive shaft flange bolts and nuts.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

Apply grease to front spindle thrust washer and front spindle part
of drive shaft.
ªAº: Grease 99000-25010

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.
ªBº: Sealant 99000-31090
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
CAUTION:

To prevent breakage of boots (wheel side and differen-
tial side), be careful not to bring them into contact with
other parts when installing drive shaft assembly.

Do not pull housing of differential side joint.
If housing is pulled, it may be detached from drive shaft.

Fill specified differential gear oil into differential case to specified
level.

YH4
GRAND
VITARA
[A]: TOKICO produced
[B]: SUMITOMO ELECTRIC produced1. Caliper pin bolt
2. Boot
3. Disc brake caliper
(Disc brake cylinder)
4. Piston seal
5. Disc brake piston
6. Cylinder boot
7. Disc brake inner pad
8. Disc brake outer pad
9. Brake caliper carrier
10. Pad spring
11. Bleeder plug
12. Bleeder plug cap
13. Caliper pin
14. Anti noise shim
15. Inner shim
Tightening torque
(a): 8.5 N.m (0.85 kg-m, 6.5 lb-ft)
(b): 8.0 N.m (0.80 kg-m, 6.0 lb-ft) [A]
[B]
5B-2 FRONT BRAKE
GENERAL DESCRIPTION
DISC BRAKE CALIPER ASSEMBLY
This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying
force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston
and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in
a clamping action on the disc. This clamping action forces the pads (linings against the disc, creating friction to
stop the vehicle.
NOTE:

Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo-
nents may result. If any component is removed or line disconnected, bleed the brake system.
Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners.

For identification of the brake caliper type, see maker name or mark on brake caliper as shown.