Suzuki GRAND VITARA - User manual

Type
User manual
Table of Contents 3- i
3
Section 3
CONTENTS
Driveline / Axle
Precautions .................................................3-1
Precautions............................................................. 3-1
Precautions for Driveline / Axle ............................. 3-1
Drive Shaft / Axle ..................................... 3A-1
Front .........................................................................3A-1
General Description .............................................3A-1
Front Drive Shaft Construction............................3A-1
Diagnostic Information and Procedures............3A-1
Front Drive Shaft Symptom Diagnosis ................ 3A-1
Repair Instructions ..............................................3A-2
Front Drive Shaft Boot and Joint Check.............. 3A-2
Front Drive Shaft Components ........................... 3A-2
Front Drive Shaft Assembly Removal and
Installation......................................................... 3A-3
Front Drive Shaft Disassembly and
Assembly .......................................................... 3A-3
Specifications.......................................................3A-6
Tightening Torque Specifications........................ 3A-6
Special Tools and Equipment .............................3A-6
Recommended Service Material ......................... 3A-6
Special Tool ........................................................ 3A-6
Rear ..........................................................................3A-7
General Description .............................................3A-7
Rear Drive Shaft Construction ............................ 3A-7
Repair Instructions ..............................................3A-7
Rear Drive Shaft Components ............................ 3A-7
Rear Drive Shaft Assembly Removal and
Installation......................................................... 3A-8
Rear Drive Shaft Disassembly and
Assembly .......................................................... 3A-8
Specifications.......................................................3A-9
Tightening Torque Specifications........................ 3A-9
Special Tools and Equipment .............................3A-9
Recommended Service Material ......................... 3A-9
Special Tool ........................................................ 3A-9
Differential................................................ 3B-1
Front .........................................................................3B-1
General Description .............................................3B-1
Front Differential Construction ............................ 3B-1
Diagnostic Information and Procedures............3B-1
Front Differential Symptom Diagnosis................. 3B-1
Repair Instructions ..............................................3B-2
Front Differential Oil Change .............................. 3B-2
Front Differential Unit Components..................... 3B-3
Front Differential Dismounting and
Remounting.......................................................3B-3
Front Differential Components ............................3B-4
Front Differential Assembly Disassembly
and Reassembly ...............................................3B-5
Front Differential Inspection ..............................3B-17
Specifications.....................................................3B-18
Tightening Torque Specifications......................3B-18
Special Tools and Equipment ...........................3B-18
Recommended Service Material .......................3B-18
Special Tool ......................................................3B-18
Rear ........................................................................3B-21
General Description ...........................................3B-21
Rear Differential Construction ...........................3B-21
Diagnostic Information and Procedures..........3B-21
Rear Differential Symptom Diagnosis ...............3B-21
Repair Instructions ............................................3B-21
Rear Differential Oil Change .............................3B-21
Rear Differential Unit Components ...................3B-21
Rear Differential Dismounting and
Remounting.....................................................3B-22
Rear Differential Components...........................3B-23
Rear Differential Assembly Disassembly
and Reassembly .............................................3B-24
Rear Differential Inspection...............................3B-36
Specifications.....................................................3B-36
Tightening Torque Specifications......................3B-36
Special Tools and Equipment ...........................3B-37
Recommended Service Material .......................3B-37
Special Tool ......................................................3B-37
Transfer .................................................... 3C-1
Motor-Shift Type (Transfer with Shift
Actuator) ................................................................3C-1
Precautions...........................................................3C-1
Transfer Warning ................................................3C-1
Precautions in Diagnosing Trouble .....................3C-1
General Description .............................................3C-1
Transfer Description............................................3C-1
Transfer Shift Control System Components........3C-2
4WD Control System Description........................3C-3
Function of 4WD Control System
Component........................................................3C-5
4WD Control System Operation..........................3C-5
4WD Control System Wiring Circuit Diagram....3C-11
Terminal Arrangement of 4WD Control
Module ............................................................3C-12
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3-ii Table of Contents
Input / Output Signal Table of 4WD Control
Module ............................................................3C-12
On-Board Diagnostic System Description.........3C-12
CAN Communication System Description.........3C-13
Diagnostic Information and Procedures..........3C-14
4WD Control System Check .............................3C-14
Transfer Position Indicator Operation Check ....3C-17
4WD Control System Operation Inspection ......3C-17
Visual Inspection ...............................................3C-18
DTC Check........................................................3C-19
DTC Clearance .................................................3C-20
DTC Table.........................................................3C-20
Fail-Safe Table..................................................3C-21
Scan Tool Data .................................................3C-22
Scan Tool Data Definitions................................3C-22
4WD Control Symptom Diagnosis.....................3C-23
Transfer Position Indicator Does Not Come
ON at Ignition Switch ON but Engine Stops....3C-24
Transfer Position Indicator Remains ON
Steady at Ignition Switch ON ..........................3C-26
DTC C1213: Transfer Switch Circuit Open .......3C-27
DTC C1214: Transfer Switch Circuit Short .......3C-28
DTC C1223 / C1235: Transfer Shift
Actuator Motor Position Switch 1 Circuit
Open / Transfer Shift Actuator Motor Position
Switch 2 Circuit Open .....................................3C-30
DTC C1224 / C1236: Transfer Shift
Actuator Motor Position Switch 1 Circuit
Short / Transfer Shift Actuator Motor Position
Switch 2 Circuit Short......................................3C-32
DTC C1227: 4L/N Switch Circuit Open .............3C-34
DTC C1228: 4L/N Switch Circuit Short .............3C-35
DTC C1230: Transfer Actuator Circuit
Malfunction......................................................3C-37
DTC C1237: Center Differential Lock Switch
Circuit Open ....................................................3C-38
DTC C1238: Center Differential Lock Switch
Circuit Short ....................................................3C-40
DTC C1240: 4WD Control Module Power
Supply Circuit Malfunction ..............................3C-41
DTC C1243: Internal Circuit Malfunction of
4WD Control Module.......................................3C-42
DTC C1246: Clutch Pedal Position (CPP)
Switch Circuit Short.........................................3C-43
DTC U1073: Control Module Communication
Buss Off ..........................................................3C-44
DTC U1100: Lost Communication with ECM ....3C-46
DTC U1101: Lost Communication with TCM ....3C-48
DTC U1121: Lost Communication with ABS
Hydraulic Unit / Control Module ......................3C-50
Inspection of 4WD Control Module and Its
Circuits ............................................................3C-51
Repair Instructions ............................................3C-54
Transfer Oil Level Check...................................3C-54
Transfer Oil Change..........................................3C-54
Transfer Oil Seal Removal and Installation.......3C-55
Transfer Switch Removal and Installation.........3C-55
Transfer Switch Inspection................................3C-56
4WD Control Module Removal and
Installation.......................................................3C-56
Transfer Assembly Dismounting and
Remounting.....................................................3C-57
Transfer Assembly Components .......................3C-58
Transfer Assembly Disassembly and
Reassembly ....................................................3C-59
Transfer Assembly Inspection ...........................3C-67
Input Gear Assembly, Counter Gear
Assembly, Front Output Shaft Assembly
and Rear Output Shaft Assembly
Components....................................................3C-69
Input Gear Assembly Disassembly and
Reassembly ....................................................3C-70
Counter Gear Assembly Disassembly
and Reassembly .............................................3C-71
Front Output Shaft Assembly Disassembly
and Reassembly .............................................3C-71
Rear Output Shaft Assembly Disassembly
and Reassembly .............................................3C-72
Specifications.....................................................3C-73
Tightening Torque Specifications......................3C-73
Special Tools and Equipment ...........................3C-73
Recommended Service Material .......................3C-73
Special Tool ......................................................3C-74
Non-Shift Type (Transfer without Shift
Actuator) ..............................................................3C-75
Precautions.........................................................3C-75
Transfer Warning ..............................................3C-75
General Description ...........................................3C-75
Transfer Construction........................................3C-75
Diagnostic Information and Procedures..........3C-76
Transfer Symptom Diagnosis............................3C-76
Repair Instructions ............................................3C-77
Transfer Oil Change..........................................3C-77
Transfer Oil Level Check......
...
..........................3C-77
Transfer Oil Seal Removal and Installation.......3C-77
Transfer Assembly Dismounting and
Remounting.....................................................3C-77
Transfer Assembly Components .......................3C-78
Transfer Assembly Disassembly and
Reassembly ....................................................3C-80
Input Gear Assembly Disassembly and
Reassembly ....................................................3C-86
Front Output Shaft Assembly Disassembly
and Reassembly .............................................3C-86
Rear Output Shaft Assembly Disassembly
and Reassembly .............................................3C-86
Specifications.....................................................3C-87
Tightening Torque Specifications......................3C-87
Special Tools and Equipment ...........................3C-87
Recommended Service Material .......................3C-87
Special Tool ......................................................3C-87
Propeller Shafts....................................... 3D-1
Precautions...........................................................3D-1
Propeller Shaft Caution .......................................3D-1
General Description .............................................3D-1
Propeller Shaft Construction ...............................3D-1
Diagnostic Information and Procedures............3D-2
Propeller Shaft Symptom Diagnosis ...................3D-2
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Table of Contents 3-iii
Repair Instructions ..............................................3D-2
Propeller Shaft Joint Check ................................3D-2
Propeller Shaft Removal and Installation ............3D-2
Propeller Shaft Disassembly and Assembly .......3D-3
Propeller Shaft Inspection ...................................3D-5
Specifications.......................................................3D-5
Tightening Torque Specifications........................3D-5
Special Tools and Equipment .............................3D-6
Recommended Service Material .........................3D-6
Special Tool ........................................................3D-6
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3-1 Precautions:
Precautions
Precautions
Precautions for Driveline / Axle
S5JB0A3000001
Differential Gear Oil Note
Refer to “Differential Gear Oil Note: in Section 00”.
Fastener Caution
Refer to “Fastener Caution: in Section 00”.
Precautions for Transfer
Refer to “Precautions in Diagnosing Trouble: Motor-Shift Type (Transfer with Shift Actuator) in Section 3C”.
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Drive Shaft / Axle: Front 3A-1
Drive Shaft / Axle
Front
General Description
Front Drive Shaft Construction
S5JB0A3111001
A constant velocity tripod joint is used on the differential side of both the right and left drive shaft assemblies. And, a
constant velocity ball joint is used on the wheel side of both the right and left drive shaft assemblies. The drive shaft
can slide through the tripod joint in the extension / contraction direction.
Diagnostic Information and Procedures
Front Drive Shaft Symptom Diagnosis
S5JB0A3114001
Condition Possible cause Correction / Reference Item
Abnormal noise: When
starting
Loose wheel nut(s) Tighten wheel nut(s) referring to “Wheel
Removal and Installation: in Section 2D”.
Loose drive shaft flange bolt(s) Tighten drive shaft flange bolt(s) referring to
“Front Drive Shaft Assembly Removal and
Installation: Front”.
Broken or damaged wheel bearing Replace referring to “Front Wheel Hub, Disc,
Nut and Bearing Check: in Section 2B”.
Abnormal noise: When
making turns
Grease leakage from boot Replace boot and apply grease referring to
“Front Drive Shaft Disassembly and Assembly:
Front”.
Worn or broken drive shaft joint Replace drive shaft joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.
Abnormal noise: When
running
Broken drive shaft joint Replace drive shaft joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.
Poorly lubricated or worn joint Lubricate or replace joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.
Loose drive shaft flange bolt(s) Tighten drive shaft flange bolt(s) referring to
“Front Drive Shaft Assembly Removal and
Installation: Front”.
Vibration Worn drive shaft joint Replace drive shaft joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.
Deformed drive shaft Replace referring to “Front Drive Shaft
Disassembly and Assembly: Front”.
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3A-2 Drive Shaft / Axle: Front
Repair Instructions
Front Drive Shaft Boot and Joint Check
S5JB0A3116001
Check boot for tear. If even a small tear is found, replace with new one.
Check drive shaft joint for wear, breakage, and any other damage. Replace if any abnormality is found.
Front Drive Shaft Components
S5JB0A3116002
I5JB0A311001-01
I5JB0A311002-03
[A]: Right side drive shaft assembly 4. Boot band (Large) 9. Drive shaft nut
: After tightening nut, caulk nut
securely.
[B]: Left side drive shaft assembly 5. Boot (Differential side) 10. Front drive shaft flange nut
1. Circlip 6. Boot band (Small) : 200 Nm (20.0 kgf-m, 145.0 lb-ft)
2. Differential side joint (Constant velocity tripod joint)
: Apply yellow grease included in spare part to joint.
7. Wheel side joint assembly (Constant velocity
ball joint)
: Never disassemble.
:80 Nm (8.0 kgf-m, 58.0 lb-ft)
3. Snap ring 8. Tripod joint spider : Do not reuse.
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Drive Shaft / Axle: Front 3A-3
Front Drive Shaft Assembly Removal and
Installation
S5JB0A3116003
Removal
1) Undo caulking (1) and remove drive shaft nut (2).
2) Hoist vehicle and remove wheel.
3) Drain front differential oil.
4) Disconnect tie-rod end from steering knuckle
referring to “Steering Knuckle Removal and
Installation: in Section 2B”.
5) Remove stabilizer joint from stabilizer bar.
6) Remove brake hose mounting bolt.
7) Remove suspension control arm referring to
“Suspension Control Arm Removal and Installation:
in Section 2B”.
8) Remove front drive shaft flange nuts (1).
9) Remove drive shaft assembly from front differential.
CAUTION
!
To prevent breakage of boots (wheel side and
differential side), do not contact them with
other parts when removing drive shaft
assembly.
Installation
CAUTION
!
Be careful not to damage oil seals and
boots when installing drive shaft.
Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.
Make sure that differential side joint is
inserted fully and its snap ring is seated as
it was.
Install drive shaft assembly by reversing removal
procedure and noting the following points.
Tighten each bolts and nuts to the specified torque
referring to “Front Drive Shaft Components: Front”
and “Front Suspension Construction: in Section 2B”.
Front Drive Shaft Disassembly and Assembly
S5JB0A3116004
Disassembly
CAUTION
!
Disassembly of wheel side joint assembly
is not allowed. If any noise or damage
exists in it, replace it as assembly.
Do not disassemble tripod joint spider. If
any malcondition is found in it, replace it
as differential side joint assembly.
1) Draw hooks (2) of boot big band together and
remove differential side boot big band (1).
I5JB0A311003-01
1
I5JB0A311004-01
I5JB0A311005-01
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3A-4 Drive Shaft / Axle: Front
2) Wipe off grease from shaft and take off snap ring (1)
using snap ring plier (2).
3) Remove tripod joint spider (1) using 3 arms puller
(2).
CAUTION
!
To prevent any problem caused by washing
solution, do not wash tripod joint except its
housing. Degreasing of tripod joint with cloth
is allowed.
4) Remove differential side boot small band, and then
pull out differential side boot from shaft.
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that tripod joint housing is washed thoroughly
and air dried.
Replace boot with new one.
CAUTION
!
Do not wash boots in degreaser such as
gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
To ensure full performance of joint as
designed, apply grease of specified
volume and color to joint.
1) Wash disassembled parts (except boots). After
washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Set new differential side small band and new
differential side boot (1) on shaft temporarily, and
then apply grease to tripod joint (2). Use specified
grease in tube included in spare parts.
4) Install tripod joint spider (3) on shaft using special
tool with hammer, directing its chamfered spline
toward wheel side, and then fasten it with new snap
ring (4) using snap ring plier (5).
Special tool
(A): 09913–80113
I5JB0A311008-01
I3RH0A311004-01
I5JB0A311009-01
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Drive Shaft / Axle: Front 3A-5
5) Apply grease (including in spare parts) to inside of
tripod joint housing (1), joint it with tripod joint.
Grease color
“A”: Yellow
Amount
“A”: 127 – 137 g (4.5 – 4.8 oz) (right side)
“A”: 170 – 180 g (6.0 – 6.3 oz) (left side)
6) Fit boot to grooves of shaft and housing.
7) Insert screw driver into boot and allow air to enter
boot so that air pressure in boot becomes the same
as atmospheric pressure.
CAUTION
!
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
durability.
8) Place differential side boot new big band (3) and new
small band (4) onto boot putting band outer end (1)
against forward rotation (2) as shown in figure.
9) Fasten differential side boot big band.
For differential side boot big band
Fasten band (1) by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57010
For differential side boot small band
Fasten band (5) securely using special tool.
NOTE
Fasten boot small band securely until
complete contact “a” is obtained.
Special tool
(A): 09943–57010
I4RS0B310003-01
I5JB0A311006-01
(A)
1
4
2
3
(A)
5
“a”
I5JB0A311007-02
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3A-6 Drive Shaft / Axle: Front
Specifications
Tightening Torque Specifications
S5JB0A3117001
NOTE
The specified tightening torque is also described in the following.
“Front Drive Shaft Components: Front”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”.
Special Tools and Equipment
Recommended Service Material
S5JB0A3118001
NOTE
Required service material is also described in the following.
“Front Drive Shaft Components: Front”
Special Tool
S5JB0A3118002
09913–80113 09943–57010
Bearing installer Band compressor
)) / )
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Drive Shaft / Axle: Rear 3A-7
Rear
General Description
Rear Drive Shaft Construction
S5JB0A3121002
Refer to “Front Drive Shaft Construction: Front”.
Repair Instructions
Rear Drive Shaft Components
S5JB0A3126007
I5JB0A312001-02
1. Differential side joint (Constant velocity tripod joint)
: Apply yellow grease included in spare part to joint.
5. Boot band (Small) 9. Rear drive shaft flange nut
2. Snap ring 6. Wheel side joint (Constant velocity ball joint)
: Never disassemble.
: 200 Nm (20.0 kgf-m, 145.0 lb-
ft)
3. Boot band (Large) 7. Tripod joint spider : 80 Nm (8.0 kgf-m, 58.0 lb-ft)
4. Boot (Differential side) 8. Drive shaft nut
: After tightening nut, caulk nut securely.
: Do not reuse.
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3A-8 Drive Shaft / Axle: Rear
Rear Drive Shaft Assembly Removal and
Installation
S5JB0A3126008
Removal
1) Undo caulking (1) of drive shaft nut (2) and then
remove drive shaft nut.
2) Hoist vehicle and remove wheel.
3) Give match mark rear drive shaft flange (3) and rear
drive shaft (4) as shown in figure, and then remove
rear drive shaft flange nuts (1), and then remove rear
drive shaft.
Installation
Install drive shaft assembly by reversing removal
procedure and noting the following points.
Install rear drive shaft (1) aligning match marks (2).
CAUTION
!
Protect oil seals and boots from any
damage, preventing them form
unnecessary contact while installing drive
shaft.
Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.
Make sure that differential side joint is
inserted fully and its snap ring is seated as
it was.
Tighten each nuts to specified torque referring to
“Rear Drive Shaft Components: Rear”.
Rear Drive Shaft Disassembly and Assembly
S5JB0A3126009
Disassembly
Refer to “Front Drive Shaft Disassembly and Assembly:
Front”.
Assembly
Assemble rear drive shaft assembly referring to “Front
Drive Shaft Disassembly and Assembly: Front” and
noting the following points which are different from that
of the front drive shaft assembly.
Apply grease to differential side joint.
Grease color
: Yellow
Amount
: 197 – 207 g (6.9 – 7.3 oz)
Install tripod joint spider (1) on shaft by using special
tool with hammer, directing its chamfered spline
toward wheel side, and then fasten it with new snap
ring (2) using snap ring plier (3).
Special tool
(A): 09913–84510
2. Match mark
I5JB0A311003-01
1
3
2
4
I5JB0A312002-02
2
1
I5JB0A312003-01
I5JB0A312004-03
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Drive Shaft / Axle: Rear 3A-9
Specifications
Tightening Torque Specifications
S5JB0A3127001
NOTE
The specified tightening torque is also described in the following.
“Rear Drive Shaft Components: Rear”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”.
Special Tools and Equipment
Recommended Service Material
S5JB0A3128001
NOTE
Required service material is also described in the following.
“Rear Drive Shaft Components: Rear”
Special Tool
S5JB0A3128002
09913–84510
Bearing installer
)
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3B-1 Differential: Front
Differential
Front
General Description
Front Differential Construction
S5JB0A3211001
The differential assembly uses a hypoid bevel pinion and gear.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and
specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between bevel pinion and
gear, it is mandatory to lubricate them by hypoid gear oil.
Diagnostic Information and Procedures
Front Differential Symptom Diagnosis
S5JB0A3214001
Condition Possible cause Correction / Reference Item
Gear noise Deteriorated or water mixed lubricant Repair and replenish referring to “Front
Differential Oil Change: Front”.
Inadequate or insufficient lubricant Repair and replenish referring to “Front
Differential Oil Change: Front”.
Maladjusted backlash between drive
bevel pinion and gear
Adjust as prescribed referring to “Front
Differential Assembly Disassembly and
Reassembly: Front”.
Improper tooth contact in the mesh
between drive bevel pinion and gear
Adjust or replace referring to “Front Differential
Assembly Disassembly and Reassembly:
Front”.
Loose drive bevel gear securing bolts Replace or retighten referring to “Front
Differential Assembly Disassembly and
Reassembly: Front”.
Damaged differential gear(s) or
differential pinion(s)
Replace referring to “Front Differential
Inspection: Front”.
Bearing noise (Constant noise) Deteriorated or water
mixed lubricant
Repair and replenish referring to “Front
Differential Oil Change: Front”.
(Constant noise) Inadequate or
insufficient lubricant
Repair and replenish referring to “Front
Differential Oil Change: Front”.
(Noise while coasting) Damaged
bearing(s) of drive bevel pinion
Replace referring to “Front Differential
Inspection: Front”.
(Noise while turning) Damaged
differential side bearing(s) or axle
bearing(s)
Replace referring to “Front Differential
Inspection: Front”.
Oil leakage Clogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level referring to “Front Differential
Oil Change: Front”.
Loose differential carrier bolts Replace or retighten.
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Differential: Front 3B-2
Repair Instructions
Front Differential Oil Change
S5JB0A3216012
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check leakage.
If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.
3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential oil drain plug (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
6) Pour new specified oil until oil level reaches bottom
of oil filler plug hole (3) as shown in figure.
NOTE
Hypoid gear oil must be used for
differential.
It is highly recommended to use API GL-5
80W-90 gear oil.
Differential oil specification
: API GL-5 (For SAE classification, refer to
viscosity chart [A] in figure.)
Differential oil capacity (Reference)
: 0.9 – 1.1 liters (1.9/1.6 – 2.3/1.9 US/Imp. pt.)
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential oil level / filler plug (b): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
I5JB0A321004-02
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3B-3 Differential: Front
Front Differential Unit Components
S5JB0A3216007
Front Differential Dismounting and Remounting
S5JB0A3216008
Dismounting
1) Lift up vehicle and drain front differential oil.
2) Remove front drive shafts referring to “Front Drive
Shaft Assembly Removal and Installation: Front in
Section 3A”.
3) Remove front suspension frame with front differential
referring to “Front Suspension Frame, Stabilizer Bar
and/or Bushings Removal and Installation: in
Section 2B”.
4) Remove mounting bolts (1), and then take off front
differential from front suspension frame (2).
2
1
3
7
(a)
5
(a)
(b)
8
6
(b)
4
(a)
5
(a)
10
(c)
9
I5JB0A321001-05
1. Front differential 8. Rear mounting bracket bolt
2. Right mounting bracket 9. Damper
3. Right mounting bolt 10. Damper bolt
4. Differential mounting bolt : 85 Nm (8.5 kgf-m, 61.5 lb-ft)
5. Rear mounting bolt : 50 Nm (5.0 kgf-m, 36.5 lb-ft)
6. Rear mounting bracket : 23 Nm (2.3 kgf-m, 17.0 lb-ft)
7. Right mounting bracket bolt
1
1
2
I5JB0A321002-01
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Differential: Front 3B-4
Remounting
Reverse dismounting procedure for remounting noting the following.
Tighten each bolts and nuts referring to “Front Differential Unit Components: Front”, “Front Drive Shaft Components:
Front in Section 3A” and “Front Suspension Frame, Stabilizer Bar and/or Bushings Components: in Section 2B”.
Fill front differential oil referring to “Front Differential Oil Change: Front”.
Front Differential Components
S5JB0A3216001
(a)
18
(a)
18
(b)
24
19
9
21
15
14
16
17
14
10
11
11
17
16
5
26
2
4
13
23
12
10
(c)
22
3
6
7
1
A
8
(a)
25
15
20
20
I5JB0A321003-08
1. Universal joint flange 17. Pinion washer
2. Hypoid gear set 18. Retainer bolt
3. Bevel pinion spacer 19. Differential side right retainer
: Apply sealant 99000-31260 to mating surface of right retainer,
carrier and rear cover.
4. Shim 20. Shim
5. Rear bearing 21. Front drive shaft retainer
: Apply sealant 99000-31260 to mating surface of drive shaft
retainer, carrier and rear cover.
6. Front bearing 22. Bevel gear bolt
: Apply thread lock cement 99000-32110 to thread part of bolt.
7. Oil seal
: Apply grease 99000-25010 to oil seal lip.
23. Rear cover
8. Flange nut
: After tightening nut so as rotation torque of bevel pinion shaft to be
in specified value, caulk nut securely.
24. Rear cover bolt No.1 bolt
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3B-5 Differential: Front
Front Differential Assembly Disassembly and
Reassembly
S5JB0A3216010
Disassembly
1) Remove front differential right mounting (1) and rear
mounting (2).
2) Drive out front drive shaft (1) from front shaft retainer
(2) using plastic hammer (3).
3) Remove differential side right retainer and front drive
shaft retainer, and then remove rear cover (1).
4) Disassembly front drive shaft retainer as follows, if
necessary.
a) Remove oil seal (1) from front drive shaft retainer
using special tool.
Special tool
(A): 09913–50121
b) Remove snap ring (1) using snap ring plier.
c) Drive out front drive shaft bearing using special
tools.
Special tool
(A): 09930–30104
(B): 09941–64511
9. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear
cover.
25. Rear cover bolt No.2 bolt
10. Differential pinion 26. Differential right case
11. Differential gear : 50 Nm (5.0 kgf-m, 36.5 lb-ft)
12. Pinion shaft : 85 Nm (8.5 kgf-m, 61.5 lb-ft)
13. Differential left case : 40 Nm (4.0 kgf-m, 29.5 lb-ft) + 50°
14. Thrust washer : Do not reuse.
15. Differential side bearing : Apply differential oil.
16. Spring washer
1
2
I5JB0A321005-01
I5JB0A321006-01
1
I5JB0A321007-01
1
(A)
I5JB0A321008-01
1
I5JB0A321009-01
(B)
(A)
I5JB0A321010-01
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Differential: Front 3B-6
5) Support differential side right retainer (1) with soft
jawed vise and remove oil seal (2) from differential
side right retainer using special tool, if necessary.
Special tool
(A): 09913–50121
6) Take out differential assembly (1), outer race and
shim all at once.
7) Pull out differential side bearing (1) using special
tools.
Special tool
(A): 09913–65135
(B): 09925–86010
8) Remove drive bevel gear (hypoid gear), differential
gears, differential pinions and pinion shaft as follows.
a) With aluminum plates (2) placed on vise first,
grip differential case with it and remove drive
bevel gear (hypoid gear) (3) by removing its bolts
(1).
b) Remove pinion shaft (1), differential gears,
washers, differential pinions, spring washers and
thrust washers.
9) Remove drive bevel pinion (hypoid gear) assembly
as follows.
a) Hold joint flange with special tool and then
remove flange nut by using power wrench (4 –
10 magnification) (2).
Special tool
(A): 09922–66021
1
(A)
2
I5JB0A321011-01
1
I5JB0A321012-02
1
(B)
(A)
I5JB0A321013-02
1. Socket wrench
3
2
1
I5JB0A321014-02
1
I5JB0A321015-02
(A)
2
1
I5JB0A321016-02
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3B-7 Differential: Front
b) Make mating marks (1) on drive bevel pinion and
companion flange.
CAUTION
!
Do not make mating mark on the coupling
surface of the flange.
c) Remove flange (2) from drive bevel pinion. Use
special tool if it is hard to remove.
Special tool
(A): 09913–65135
(B): 09925–88210
d) Remove drive bevel pinion (1) with rear bearing,
shim and spacer from carrier.
If it is hard to remove, screw an used nut (2) into
drive bevel pinion and hammer (3) on that nut
with a plastic hammer but never directly on drive
bevel pinion.
e) Remove drive bevel pinion rear bearing (2) by
using bearing puller (3) and hydraulic press.
CAUTION
!
To avoid rear bearing from being damaged,
support it at flat side of bearing puller.
10) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
11) Using a hammer and brass bar (1), drive out front
bearing outer race (2).
2
(B)
(A)
2
1
I5JB0A321017-02
3
2
1
I5JB0A321018-01
1. Drive bevel pinion
I1JA01322006-01
(A)
1
I5JB0A321019-01
I5JB0A321020-01
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Suzuki GRAND VITARA - User manual

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